SERVICE BULLETINFUEL INJECTION PUMP

NEW PRODUCTSDENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT : HP3/HP4 SUPPLY PUMP PRODUCT LIST

1. OutlineThis 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, andexterior diagrams by part number.

2. List of Pump Part Numbers by Manufacturer2.1. TOYOTA

2.2. ISUZU

Engine Model DENSOPart Number

CustomerPart Number

1KD 294000-001# 22100-30021-F

1CD HU294000-006#(HU294000-010#)

22100-0G010-C(22100-0G010-B)

1KD/2KD SM294000-011# 22100-0L010-F

1CD 294000-017# 22100-27020-A

1KD/2KD SM294000-0350 22100-0L020

1KD 294000-038# 22100-30050(22100-458F2 )

Engine Model DENSOPart Number

CustomerPart Number

CustomerOEM Part NumberOPEL Part Number

4EE2 HU294000-007#(294000-015#)

8-97313862-2(8-97313862) 97313862

- (High-Speed Edition) SM294000-023# 8-97311373-3 -

4HK1 294000-026# 8-97328886-0 -

6HK1 294050-002# 8-97602049-1 -

ECD04-05ENovenber, 2004

00400509E

SERVICE DEPARTMENT0410-IT-015 Printed in Japan

2

2.3. HINO

2.4. MAZDA

2.5. MITSUBISHI (MFTBC)

2.6. JOHN DEERE

2.7. NISSAN MOTOR

2.8. Hyundai

Engine Model

DENSOPart Number

CustomerPart Number

CustomerOEM Part Number

TOYOTA Part Number NISSAN DIESELPart Number

N04C 294000-019# 22730-1261B 22100-78190 -

J05D 294000-025# 22730-1321A - 16730-Z5002

J08E 294050-001# 22730-1311A - 16730-Z5001

Engine Model DENSOPart Number

CustomerPart Number

RF-DI 294000-004# RF5C 13 800A

Engine Model DENSOPart Number

CustomerPart Number

6M60T 294050-005# ME302145

Engine Model DENSOPart Number

CustomerPart Number

4045T,6068T 294000-005# RE507959

Engine Model DENSOPart Number

CustomerPart Number

YD1-K2294000-012# 16700 AW403

HU294000-016# 16700 AW420

Engine Model DENSOPart Number

CustomerPart Number

W (D4DA) 294000-029# 33100-45700

00400056E

Common Rail System for ISUZU

SERVICE MANUAL

OPERATION4HK1 / 6HK1 Type Engine

February, 2004

Diesel Injection Pump

FORWARD

To meet the high pressurization requirements for the engine to deliver cleaner exhaust gas emissions, lower fuelconsumption and reduced noise, advanced electronic control technology is being adopted in the fuel injection system.This manual covers the electronic control model Common Rail system with HP3/HP4 pump for the ISUZU 4HK1/6HK1type engines which are used to ELF and GM 560 series respectively. Complex theories, special functions andcomponents 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 configurationof the DENSO manufactured components and brief diagnostic information.

TABLE OF CONTENTS

1. Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. System Components Parts Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2-1. Outline of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2. Outline of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3. Fuel System and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-1. Description of Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-2. Description of Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3-3. Various Types of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243-4. Engine ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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1. Product Application1-1. Application

1-2. System Components Parts Numbers

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

Parts Name DENSO Parts NumberCar Manufacturer Parts

NumberReference

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

275800-2812 8973750190 4HK1

275800-2822 8973750200

2-2. Outline of SystemA. Composition

The common rail system consists primarily of a supply pump, rail, injectors, and engine ECU.

a. 4HK1

b. 6HK1

Q000737E

Fuel temperature sensor

Vehicle speedAccelerator opening

Intake air pressureIntake air temperature

Coolant temperature

Crankshaft positionCylinder recognition sensor

Engine ECU

Rail

Intake airflow rate

Rail pressuresensor

Supply pump

Fuel temperaturesensor SCV (suction

control valve)

Pressure limiter

Fuel tank

Injector

Q000523E

Fuel temperature sensor

Vehicle speedAccelerator opening

Intake air pressureIntake air temperature

Coolant temperature

Crankshaft positionCylinder recognition sensor

Engine ECU

Rail

Intake airflow rate

Rail pressuresensor

Supply pump

Fuel temperaturesensor SCV (suction

control valve)

Pressure limiter

Fuel tank

Injector

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