MAZDA Zexel & Denso injection pump manual

Training Manual Advanced Diesel Engine Management CT-L3004 MME Technical Training 2004

No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. © 2004 Mazda Motor Europe GmbH Technical Training Department

Adv. Diesel Engine Management Table of Contents Curriculum Training Introduction ...................................................................................... 00-1 Zexel Injection Pump System .......................................................... 01-1 Features .................................................................................................... 01-1 Intake-air System........................................................................................... 01-2 Features .................................................................................................... 01-2 Parts Location ........................................................................................... 01-3 System Overview ...................................................................................... 01-4 Turbocharger ............................................................................................ 01-5 Fuel System ................................................................................................... 01-7 Parts Location ........................................................................................... 01-7 System Overview ...................................................................................... 01-8 Injection Pump .......................................................................................... 01-9 Low-pressure System ............................................................................. 01-10 Features ........................................................................................... 01-10 High-pressure System............................................................................. 01-10 Features ........................................................................................... 01-10 Axial-piston Distributor Pump ........................................................... 01-11 Pressure Valves................................................................................ 01-13 Injectors ............................................................................................ 01-14 Diagnostics ....................................................................................... 01-16 Injection Amount Control ......................................................................... 01-17 Features ........................................................................................... 01-17 Electronic Governor .......................................................................... 01-18 Control Sleeve Position Sensor ........................................................ 01-21 Injection Pump PROM ...................................................................... 01-23 Fuel Shut-off Valve .......................................................................... 01-24 Diagnostics ....................................................................................... 01-25 Injection Timing Control .......................................................................... 01-26 Features ........................................................................................... 01-26 Timer Device .................................................................................... 01-27 Timer Control Valve .......................................................................... 01-28 Timer Position Sensor ...................................................................... 01-30 Pump Speed Sensor......................................................................... 01-32 Diagnostics ....................................................................................... 01-33 Emission System......................................................................................... 01-34 Parts Location ......................................................................................... 01-34 System Overview .................................................................................... 01-35 Exhaust System ...................................................................................... 01-36 Features ........................................................................................... 01-36 Exhaust Gas Recirculation System ......................................................... 01-36 Features ........................................................................................... 01-36 Intake Shutter Valve ......................................................................... 01-37 Diagnostics ....................................................................................... 01-38

Table of Contents Adv. Diesel Engine Management Curriculum Training Control System ............................................................................................ 01-39 Parts Location ......................................................................................... 01-39 Block Diagram......................................................................................... 01-40 Relationship Chart .................................................................................. 01-42 Powertrain Control Module...................................................................... 01-43 Features ........................................................................................... 01-43 Sensors ................................................................................................... 01-43 Features ........................................................................................... 01-43 Crankshaft Position Sensor .............................................................. 01-44 Actuators ................................................................................................. 01-46 Features ........................................................................................... 01-46 Immobilizer System .......................................................................... 01-46 Denso Injection Pump System ........................................................ 02-1 Features ..................................................................................................... 02-1 Intake-air System .................................................................................................. 02-2 Features .................................................................................................... 02-2 Parts Location ........................................................................................... 02-3 System Overview ...................................................................................... 02-4 Fuel System ................................................................................................... 02-5 Parts Location ........................................................................................... 02-5 System Overview ...................................................................................... 02-6 Injection Pump .......................................................................................... 02-7 Low-pressure System ............................................................................... 02-8 Features ............................................................................................. 02-8 High-pressure System............................................................................... 02-9 Features ............................................................................................. 02-9 Axial-piston Distributor Pump ............................................................. 02-9 Injectors ............................................................................................ 02-12 Diagnostics ....................................................................................... 02-13 Injection Amount Control ......................................................................... 02-14 Features ........................................................................................... 02-14 Spill Valve ......................................................................................... 02-14 Injector Driver Module....................................................................... 02-17 Fuel Shut-off Valve ........................................................................... 02-20 Diagnostics ....................................................................................... 02-21 Injection Timing Control .......................................................................... 02-22 Features ........................................................................................... 02-22 Pump Speed Sensor......................................................................... 02-22 Diagnostics ....................................................................................... 02-24

Adv. Diesel Engine Management Table of Contents Curriculum Training Emission System......................................................................................... 02-25 Parts Location ......................................................................................... 02-25 System Overview .................................................................................... 02-26 Exhaust System ...................................................................................... 02-27 Features ........................................................................................... 02-27 Exhaust Gas Recirculation System ......................................................... 02-27 Features ........................................................................................... 02-27 Control System ............................................................................................ 02-28 Parts Location ......................................................................................... 02-28 Block Diagram......................................................................................... 02-29 Relationship Chart .................................................................................. 02-31 Powertrain Control Module...................................................................... 02-32 Features ........................................................................................... 02-32 Sensors ................................................................................................... 02-32 Features ........................................................................................... 02-32 Crankshaft Position Sensor .............................................................. 02-33 Actuators ................................................................................................. 02-35 Features ........................................................................................... 02-35 Immobilizer System .......................................................................... 02-36 On-board Diagnostic System .......................................................... 03-1 General ..................................................................................................... 03-1 Malfunction Indicator Light .......................................................................... 03-2 Data Link Connector ..................................................................................... 03-3 Diagnostic Trouble Codes ............................................................................ 03-5 DTC Status ............................................................................................... 03-6 Fault Detection Function .............................................................................. 03-7 Monitoring Strategy for Sensors................................................................ 03-7 Monitoring Strategy for Actuators.............................................................. 03-9 Monitoring Strategy for PCM................................................................... 03-11 Fail-safe Function........................................................................................ 03-11 Fail-safe Strategy for Sensors................................................................. 03-11 Fail-safe Strategy for Actuators............................................................... 03-12 European On-board Diagnostics ............................................................... 03-13 General ................................................................................................... 03-13 Type Approval and Testing ..................................................................... 03-13 Definitions ............................................................................................... 03-15 Monitors .................................................................................................. 03-16 MIL Activation and Fault Storage ............................................................ 03-21 Freeze Frame Data ................................................................................. 03-25 Tamper Protection .................................................................................. 03-27 Diagnostics ............................................................................................. 03-28

Table of Contents Adv. Diesel Engine Management Curriculum Training Engine Mechanical System ............................................................. 04-1 General ..................................................................................................... 04-1 Compression Pressure ................................................................................. 04-1 Valve Timing .................................................................................................. 04-2 Valve Clearance ............................................................................................. 04-3 Diagnostics .................................................................................................... 04-4 Diagnostic Process .......................................................................... 05-1 General ..................................................................................................... 05-1 Basic Checks for Troubleshooting .............................................................. 05-2 List of Abbreviations........................................................................ 06-1

Adv. Diesel Engine Management Introduction Curriculum Training 00-1 Introduction • Ever stricter exhaust and noise emission regulations and the demand for low fuel consumption impose increasing demands on the fuel injection system of the diesel engine. In order to fulfill these requirements the mechanically controlled diesel injection systems have been superseded by electronically controlled systems. While the Common Rail Systems used on Mazda vehicles have already been covered by the course “Basic Diesel Engine Management” (CT-L2005) this course describes the more complex Injection Pump Systems, which require comprehensive system knowledge. • The following fuel injection systems are covered in this course: – Zexel injection pump system (B2500 UN with WL-3 or WLT-3 engine) – Denso injection pump system (323 BJ, 626 GF/GW and Premacy CP with RF-T engine) Zexel P • In addition, this training course provides information about the following items: – On-board diagnostic system (incl. European on-board diagnostics) – Engine mechanical system – Diagnostic process

Introduction Adv. Diesel Engine Management 00-2 Curriculum Training Notes

Zexel Injection Pump System Curriculum Training 01-1 Zexel Injection Pump System Features • The B2500 UN with WL-3/WLT-3 engine is equipped with the Zexel injection pump system NP-VE4. This system has the following features: – Axial piston-type injection pump with electronic governor – One-spring injectors – Injection pump pressure of max. 80 MPa Zexel P NOTE: Some of the components of the Zexel injection pump system are very similar in design and operation to those of the common rail systems. Therefore this section only describes the components which are new or operate in a different way to those of the common rail systems.

Intake-air System Zexel Injection Pump System 01-2 Curriculum Training Intake-air System Features • The intake-air system of the Zexel injection pump system has the following features: – Hot wire-type mass air flow sensor with integrated intake air temperature sensor (similar to that of the Denso common rail system) – Turbocharger with fixed geometry turbine and boost pressure control valve with spring-loaded damper for vehicles with WL-3 engine – Turbocharger with fixed geometry turbine and boost pressure control valve with pressure actuator for vehicles with WLT-3 engine (similar to that of the Bosch common rail system) – Charge-air cooler (similar to that of the Denso common rail system) – Manifold absolute pressure sensor (similar to that of the Denso common rail system) – Intake air temperature sensor (similar to that of the Denso common rail system) – Variable swirl control valves have been cancelled.

MAZDA Zexel & Denso injection pump manual

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