Opel Engine 2003 OPEL 4EE2 Type Common Rail Repair Manual PDF | Page 2

0
FORWARD
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.
This manual covers the electronic control model Common Rail system with HP3 pump for the
ISUZU 4EE2 type engine which is used to OPEL CORSA and MERIVA. Complex theories, spe-
cial functions and 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 of the DENSO manufactured components and brief diagnostic infor-
mation.
TABLE OF CONTENTS
1. Product Application ----------------------------------------------------------------------------------- 1
1.1 Application ----------------------------------------------------------------------------------------------------------------1
1.2 System Components Parts Numbers ------------------------------------------------------------------------------ 1
2. Outline ---------------------------------------------------------------------------------------------------- 2
2.1 Features of System ----------------------------------------------------------------------------------------------------- 2
[1] System Characteristics --------------------------------------------------------------------------------------------- 2
[2] Comparison to the Conventional System ----------------------------------------------------------------------- 3
2.2 Outline of System ------------------------------------------------------------------------------------------------------- 4
[1] Composition ----------------------------------------------------------------------------------------------------------- 4
[2] Operation --------------------------------------------------------------------------------------------------------------- 4
[3] Fuel System ------------------------------------------------------------------------------------------------------------ 5
[4] Control System -------------------------------------------------------------------------------------------------------- 5
3. Construction and Operation------------------------------------------------------------------------- 6
3.1 Description of Main Components ----------------------------------------------------------------------------------- 6
[1] Supply Pump (HP3) -------------------------------------------------------------------------------------------------- 6
[2] Description of Supply Pump Components ---------------------------------------------------------------------- 11
[3] Rail -----------------------------------------------------------------------------------------------------------------------14
[4] Injector ------------------------------------------------------------------------------------------------------------------ 16
3.2 Description of Control System Components --------------------------------------------------------------------- 19
[1] ECU (Electronic Control Unit) ------------------------------------------------------------------------------------- 19
[2] Description of Sensors ---------------------------------------------------------------------------------------------- 19
[3] EGR Valve (Exhaust Gas Recirculation Valve) --------------------------------------------------------------- 21
3-3 Various Types of Controls --------------------------------------------------------------------------------------------- 22
[1] Outline ------------------------------------------------------------------------------------------------------------------- 22
[2] Fuel Injection Quantity Control ------------------------------------------------------------------------------------ 23
[3] Fuel Injection Timing Control -------------------------------------------------------------------------------------- 25
[4] Fuel Injection Rate Control ----------------------------------------------------------------------------------------- 26
[5] Fuel Injection Pressure Control ----------------------------------------------------------------------------------- 26
[6] Other Controls --------------------------------------------------------------------------------------------------------- 26
4. External Wiring Diagram ----------------------------------------------------------------------------- 27
4.1 ECU External Wiring Diagram --------------------------------------------------------------------------------------- 27
4.2 ECU Connector Diagram ---------------------------------------------------------------------------------------------- 29
[1] ECU Connector Terminal Layout --------------------------------------------------------------------------------- 29
[2] Terminal Connections ----------------------------------------------------------------------------------------------- 29

Opel Engine 2003 OPEL 4EE2 Type Common Rail Repair Manual Summary of Content

0FORWARDTo meet the high pressurization requirements for the engine to deliver cleaner exhaust gasemissions, lower fuel consumption and reduced noise, advanced electronic control technologyis being adopted in the fuel injection system.This manual covers the electronic control model Common Rail system with HP3 pump for theISUZU 4EE2 type engine which is used to OPEL CORSA and MERIVA. Complex theories, spe-cial functions and components made by manufacturers other than DENSO are omitted from thismanual.This manual will help the reader develop an understanding of the basic construction, operationand system configuration of the DENSO manufactured components and brief diagnostic infor-mation.TABLE OF CONTENTS1. Product Application ----------------------------------------------------------------------------------- 11.1 Application ----------------------------------------------------------------------------------------------------------------11.2 System Components Parts Numbers ------------------------------------------------------------------------------ 12. Outline ---------------------------------------------------------------------------------------------------- 22.1 Features of System ----------------------------------------------------------------------------------------------------- 2[1] System Characteristics --------------------------------------------------------------------------------------------- 2[2] Comparison to the Conventional System ----------------------------------------------------------------------- 32.2 Outline of System ------------------------------------------------------------------------------------------------------- 4[1] Composition ----------------------------------------------------------------------------------------------------------- 4[2] Operation --------------------------------------------------------------------------------------------------------------- 4[3] Fuel System ------------------------------------------------------------------------------------------------------------ 5[4] Control System -------------------------------------------------------------------------------------------------------- 53. Construction and Operation------------------------------------------------------------------------- 63.1 Description of Main Components ----------------------------------------------------------------------------------- 6[1] Supply Pump (HP3) -------------------------------------------------------------------------------------------------- 6[2] Description of Supply Pump Components ---------------------------------------------------------------------- 11[3] Rail -----------------------------------------------------------------------------------------------------------------------14[4] Injector ------------------------------------------------------------------------------------------------------------------ 163.2 Description of Control System Components --------------------------------------------------------------------- 19[1] ECU (Electronic Control Unit) ------------------------------------------------------------------------------------- 19[2] Description of Sensors ---------------------------------------------------------------------------------------------- 19[3] EGR Valve (Exhaust Gas Recirculation Valve) --------------------------------------------------------------- 213-3 Various Types of Controls --------------------------------------------------------------------------------------------- 22[1] Outline ------------------------------------------------------------------------------------------------------------------- 22[2] Fuel Injection Quantity Control ------------------------------------------------------------------------------------ 23[3] Fuel Injection Timing Control -------------------------------------------------------------------------------------- 25[4] Fuel Injection Rate Control ----------------------------------------------------------------------------------------- 26[5] Fuel Injection Pressure Control ----------------------------------------------------------------------------------- 26[6] Other Controls --------------------------------------------------------------------------------------------------------- 264. External Wiring Diagram ----------------------------------------------------------------------------- 274.1 ECU External Wiring Diagram --------------------------------------------------------------------------------------- 274.2 ECU Connector Diagram ---------------------------------------------------------------------------------------------- 29[1] ECU Connector Terminal Layout --------------------------------------------------------------------------------- 29[2] Terminal Connections ----------------------------------------------------------------------------------------------- 29