denso cr - hp3 nissan

SERVICE BULLETINFUEL INJECTION PUMP

NEW PRODUCTSDENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT :NISSAN YD22 ENGINE COMMON RAIL SYSTEM

1.OutlineThis is a notification concerning changes to portions of the CRS (Common Rail System)installed in the NISSAN X-TRAIL YD22 engine to meet Euro 4 emission regulations.Basic construction/operation and control have not changed. Please refer to the "Common RailSystem for NISSAN YD1-K2 Type Engine" Service Manual issued in June, 2003 for detailsconcerning these items (publication code: 00400013.)

1.1. Change Items(1) Items that have changed to meet Euro 4 emission regulations • An electronic control throttle has been adopted. • Rail pressure has changed from 160Mpa to 180Mpa. • Rail pressure limiter opening pressure has changed. • A DPF (Diesel Particulate Filter) system with oxidation catalyst has been adopted as an option

setting (refer to page six for details.)(2) Items that have changed to due to the commonization of CRS components

The items below have changed due to commonization with other CRSs. • A multi-hole filter has been adopted for the fuel supply portion of injectors. • Injection quantity control method has changed from adjustable resistance correction to QR cor-

rection.

2. APPLICABLE VEHICLE MODEL

3. APPLICABLE PARTS LIST

Vehicle Name Engine Model Displacement(Volume) Destination Start of Production

X-TRAIL YD22 2.2 L Europe October, 2005

Part Name DENSOPart Number

ManufacturerParts Number Remarks

Supply pump 294000 - 047# 16700 - ES60A HP3 Type

Injector 095000 - 602# 16600 - ES60A G2 Type

Rail 095440 - 086# 17520 - ES60A -

ECD06-02EFebruary, 2006

00400550E

SERVICE DEPARTMENT0602-IT-001 Printed in Japan

2

Engine ECU

275800 - 444# 23710 - ES60A 4WD with DPF, OBD compliant.

275800 - 450# 23710 - ES62A 4WD with DPF,VDC; OBD compliant.

275800 - 451# 23710 - ES70A 2WD with DPF, OBD compliant.

275800 - 452# 23710 - ES72A 2WD with DPF,VDC; OBD compliant.

275800 - 445# 23710 - ES65A 4WD, OBD compliant.

275800 - 453# 23710 - ES66A 4WD

275800 - 454# 23710 - ES67A 4WD with VDC, OBD compliant.

275800 - 455# 23710 - ES68A 4WD with VDC.

275800 - 456# 23710 - ES75A 2WD, OBD compliant.

275800 - 458# 23710 - ES77A 2WD with VDC, OBD compliant.

Crankshaft Position Sensor 949979 - 009# 23731 - AW400 -

Cylinder Recognition Sensor 949979 - 119# 23731 - AW410 -

Electronic Control Throttle 197920 - 003# 16119 - ES60A Only DPF (Option)

Exhaust gas Temperature Sensor(Inlet Side Catalyst)

265600 - 118# 22630 - ES60B Only DPF (Option)

Exhaust gas Temperature Sensor(Outlet Side Catalyst)

265600 - 119# 22630 - ES61B Only DPF (Option)

Differential Pressure Sensor Assy 104990 - 112# 22770 - ES60A

Only DPF (Option)Differential Pressure Sensor 104990 - 128# 22771 - ES60A

Differential Pressure Temperature Sensor 179700 - 048# 22630 - ES60C

A/F Sensor 211200 - 701# 226A3 - ES60A Only DPF (Option)

VDC: Vehicle Dynamics Control

OBD: On Board Diagnosis

Part Name DENSOPart Number

ManufacturerParts Number Remarks

3

4. EXPLANATION OF CHANGE ITEMS4.1. Injector(1) Outline • A multi-hole filter has been adopted for injectors. • Injection quantity control method has changed from adjustable resistance correction to QR cor-

rection.(2) Exterior View Diagram

Solenoid Valve

Multi-Hole Filter

Q001544E

Command Piston

QR code 30 Base 16 Characters

Nozzle Spring

Nozzle Needle

Pressure Pin

4

(3) QR CodeThe injection quantity adjustment point has increased dramatically by adopting the QR Code.This has also led to equal flow characteristics from each injector and has acted to raise com-bustion efficiency and lower emission.

The correction point is detailed below

(4) Service Work CautionsWhen replacing injectors with QR codes, or the engine ECU, it is necessary to record the IDcodes in the ECU. (If the ID Codes for the installed injectors are not registered correctly, enginefailure such as rough idling and noise will result). Use specialized NISSAN service tools at aNISSAN dealer to record the ID codes.

a. Replacing the Injector

Q001545E

ID Codes (30 base 16 characters)Base 16 characters noting fuel injection quantity correction information for market service use

QR Codes (9.9mm)

Inje

ctio

n Q

ua

ntity

Q

180 Mpa

100 Mpa

70 Mpa

135 Mpa

25 Mpa

Actuating Pulse Width TQQ001546E

Q001547E

"No correction resistance. Cannot be recognized electrically"

Replaced injector

Engine ECU

* Injector ID code must be registered with the engine ECU

5

b. Replacing the Engine ECU

4.2. Electronic Control Throttle(1) Outline

The electronic control throttle is positioned upstream of the intake manifold EGR valve andoperates in cooperation with the DPF system. In order to accomplish PM combustion and incineration, exhaust gas temperature is increasedby compressing intake air. The quantity of compressed intake air is controlled by positioningthe throttle at the optimum angle (refer to page six for details on the DPF system.)

(2) OperationA DC motor rotates to control throttle angle according to signals from the engine ECU.When complete combustion of PM is required, throttle angle is controlled by the engine ECU tomeet engine load conditions.

Q001548E

"No correction resistance. Cannot be recognized electrically"

* Injector ID code must be registered with the engine ECU

Replaced engine ECU

Injectors

VTA1

From Engine ECU

(Motor Actuation signal)

To Engine ECU

(Throttle Opening Signal

VTA1

IC 1IC 2

VTA2

VTA2

E2

E2

M+

M-

Vc

Vc M+ M-Q001549E

M

< Electronic Control Throttle >

Throttle

6

4.3. DPF SYSTEM(1) Outline

A DPF (Diesel Particulate Filter) system with oxidation catalyst has been adopted as an optionsetting.The DPF traps PM (Particulate Matter) from within the exhaust gas and uses combustion andincineration disposal to achieve a reduction in PM.

(2) System configuration

(3) Controla. DPF control

As the DPF captures and accumulates PM, it clogs causing a difference in pressure across theDPF. This difference in pressure is detected by the differential pressure sensor. Combustionand incineration of PM is then performed at a set differential pressure value.Combustion and incineration of PM is accomplished by increasing the temperatures of theexhaust gas and DPF via injection control (see below.)Exhaust gas temperature is increased by retarding the pre-injection and main injection dura-tions until it reaches the oxidation catalyst activation temperature. HC (Hydrocarbon) is thenadded by the post-injection, causing the oxidation catalyst to produce heat. The temperature ofthe DPF increases until it reaches the self-combusting temperature for the PM.

b. Injection controlThe engine ECU determines injection interval by controlling times "A", "B" and "C". First, themain injection interval (time "A") is determined. Then the pre-injection interval (time "B") isdetermined based on value "A". Finally, the post-injection interval (time "C") is determined.In the DPF system, control over the retardation of pre and main injection intervals is added tothe conventional control, as well as a post-injection controlled by time "C."

Q001550E

Engine ECU

A/F Sensor

To Muffler

Exhaust Temperature Sensor

From Exhaust Manifold

Differential Pressure Sensor

Differential Pressure

Temperature Sensor

DPF (With Oxidation Catalyst)DPFOxidation Catalyst

TDC C

A

Main InjectionPre Injection

Conventional Injection Pattern

Post Injection

Q001551E

B

Increased

DPF Temperature

Increased Emission Gas Temperature

7

5. DTC (DIAGNOSTIC TRROUBLE CODE) CHART • In accompaniment with the DPF system, DTCS have been added. • Due to a change in injector correction method, DTCs have been erased. • DTCs have been added. Please refer to the chart below for details.

DTC Code(SAE Code) Detection Item Description of

Diagnosis Trouble area Remarks

P0045

Turbo Charger Boost Control Solenoid Circuit/Open

An improper PWM (Pulse Width Modulation) signal is sent to Engine ECU through Turbo Charger Boost Control Solenoid

Harness or connectors(Turbo Charger Boost Control Solenoid circuit is open.)

P0130 A/F Sensor CircuitEngine ECU detects the A/F Sensor circuit is shorted.

Harness or connectors(A/F Sensor circuit is shorted.)A/F sensor

Only DPF System

P0131 A/F Sensor Circuit Low Voltage

An excessively low voltage from the sensor is sent to Engine ECU.

Harness or connectors(A/F Sensor circuit is shorted to ground.)A/F sensor

Only DPF System

P0132 A/F Sensor Circuit High Voltage

An excessively high voltage from the sensor is sent to Engine ECU.

Harness or connectors(A/F Sensor circuit is shorted to power.)

Only DPF System

P0134A/F Sensor Circuit No Activity Detected

Engine ECU detects the A/F Sensor circuit is opened.

Harness or connectors(A/F Sensor circuit is opened.)A/F Sensor

Only DPF System

P0135 A/F Sensor Heater Circuit

Engine ECU detects the A/F Sensor Heater circuit is opened or shorted to ground/power.

Harness or connectors(A/F Sensor Heater circuit is open or shorted.)A/F SensorEngine ECU

Only DPF System

P0380 Glow Plug CircuitAn improper voltage signal is sent to Engine ECU through Glow Plug

Harness or connectors(Glow plug circuit is open.)Glow Plug

P0404

Exhaust Gas Recirculation Control Circuit Range/Performance

Exhaust Gas Recirculation valve position is not in the normal pattern when engine is running.

Harness or connectors(Exhaust Gas Recirculation Control circuit is open.)Exhaust Gas Recirculation valve

P0427Exhaust Gas Temperature Sensor Low

An excessively low voltage from the sensor is sent to Engine ECU

Harness or connectors(The sensor circuit is open or shorted.)Exhaust Gas Temperature sensor (in front of DPF)

Only DPF System

P0428Exhaust Gas Temperature Sensor High

An excessively high voltage from the sensor is sent to Engine ECU

Harness or connectors(The sensor circuit is open or shorted.)Exhaust Gas Temperature sensor (in front of DPF)

Only DPF System

8

P0437Exhaust Gas Temperature Sensor Low


Harness or connectors(The sensor circuit is open or shorted.)Exhaust Gas Temperature sensor (at the back of DPF)

Only DPF System

P0438Exhaust Gas Temperature Sensor High


Harness or connectors(The sensor circuit is open or shorted.)DPF Temperature sensor (at the back of DPF)

Only DPF System

P0471

Differential Pressure Sensor Range/Performance

Differential Pressure sensor signal is not in the normal pattern when engine is running

Differential Pressure sensor Only DPF System

P0472Differential Pressure Sensor Low


Harness or connectors(The sensor circuit is open or shorted.)Differential Pressure sensor

Only DPF System

P0473Differential Pressure Sensor High


Harness or connectors(The sensor circuit is open or shorted.)Differential Pressure sensor

Only DPF System

P0478 Exhaust Pressure sensing pipe fitting

Engine ECU detects the Exhaust Pressure sensing pipe fitting is unfasten/reverse connection

Exhaust Pressure sensing pipe Only DPF System

P0501Vehicle Speed Sensor Range/Performance

Engine ECU detects the Vehicle Speed Sensor is abnormal change. (signal)

Harness or connectors(The sensor circuit is open or shorted.)Vehicle Speed Sensor

P0502 Vehicle Speed Sensor Low

Engine ECU detects the Vehicle Speed Sensor is Low Input. (CAN signal)


P0503 Vehicle Speed Sensor High

Engine ECU detects the Vehicle Speed Sensor is High Input. (CAN signal)


P0504 Brake Switch Invalid

Engine ECU detects two Brake Switch correlation's abnormal

Harness or connectors(Brake Switch circuit is open or shorted.)Brake Switch

P0580Cruise Control Multi-Function Input Circuit Low

An excessively low voltage from the Cruise Control switch is sent to Engine ECU.

Harness or connectors(Cruise Control switch circuit is open or shorted.)Cruise Control switch (steering switch)



9

P0581Cruise Control Multi-Function Input Circuit High

An excessively high voltage from the Cruise Control switch is sent to Engine ECU

Harness or connectors(Cruise Control switch circuit is open or shorted.)Cruise Control switch (steering switch)

P0638Throttle Actuator Control Range/Performance

Throttle position sensor signal is not in the normal pattern when engine is running

Throttle Actuator Only DPF System

P1472Exhaust pressure Temperature Sensor Low


Harness or connectors(The sensor circuit is open or shorted.) Exhaust pressure temperature sensor low

Only DPF System

P1473Exhaust pressure Temperature Sensor High


Harness or connectors(The sensor circuit is open or shorted.) Exhaust pressure temperature sensor low

Only DPF System

P1622 QR code error Engine ECU detects QR code data is non-writing. Engine ECU

P1623 QR code error ECM detects QR code data is abnormal. Engine ECU

P2002Particulate Trap Efficiency Below Threshold

Engine ECU detects the Particulate filter is accumulating particulate matter too much

Particulate filter Only DPF System

P2118

Throttle Actuator Control Motor Current Range/Performance

Engine ECU detects the Throttle Actuator Control Motor circuit is shorted to ground/power

Harness or connectors(Throttle Actuator Control Motor circuit is shorted.)Throttle Actuator

Only DPF System

P2119

Throttle Actuator Control Throttle Body Range/Performance

Throttle position sensor signal is not in the normal pattern when ignition-key OFF.

Throttle Actuator Only DPF System

P2297

Atmospheric Pressure Circuit Range/Performance

Engine ECU detects a current of A/F sensor is excessively high or low.

A/F sensor Only DPF System

P2621 Throttle Position Output Circuit Low


Harness or connectors(The sensor circuit is open or shorted.)Throttle Position sensor

Only DPF System

P2622 Throttle Position Output Circuit High


Harness or connectors(The sensor circuit is open or shorted.)Throttle Position sensor

Only DPF System



10

6. EXTERNAL WIRING DIAGRAM6.1. ENGINE ECU EXTERNAL WIRING DIAGRUM

Q001554E

VNT PWM Drive

RFRH

RFRM

RFRL

Control (ECCS) Relay

P1P3

P3

P4

P2

P3

P4

P2

Glow Plug Relay

Fuel Pump Relay

Key ACC

SOFF

Battery

BATT

Starter

Motor

Starter Cut System

Body Ground

NE+

NE-

46

65

A-VCC4

Crankshaft

Position

Sensor

Cylinder

Recognition

Sensor

A/F Sensor

A/F Heater

45

BATT121

GROW RLY37

PD PRES53

PDPRESRTN72

IG-SW107

IG-SW108

STA-SW99

25

26

86

EGR2

EGR3

EGR4

27

EGR128

ISV -118

ISV +116

ACRLY

ISVP

20

+BP119

+BP120

M-REL105

M-REL113

VNT6

RFRH17

RFRM16

CAN1-H

CAN1-L

95

STRG102

STRGRTN

Steering

Switch 103

87

RFRL15

IM Immobilizer ANT

Exhaust Pressure

Temperature Sensor

Exhaust Temperature

Sensor 1 (Front side of DPF)

Consult2

Brake Switch 2

BATT

AcceleratorPosition Sensor

112

K-line 89

BRK2

BRK1

101

102

A-VCC1 82

APS1 83

APS1 GND 84

AF 93

AFRTN 85

AFHT 34

AFHTGND 35

A-VCC2 90

APS2 91

APS2 GND 92

DPF-P-TEMP 79

DPF TMP1 RTN 75

DPF TMP 1 56

Exhaust Temperature

Sensor 2 (Rear side of DPF)DPF TMP2 RTN 76

DPF P SNS 58 Differential Pressure Sensor

Fuel Level Switch

FPR 39

14

Refrigerant Pressure Sensor

DPF Light

18

DPF TMP 2 57

G+

G-

47

66

S-GND 67

IG

VDC UNITElectronic Control Throttle

DC Motor

EGR Motor

AC Relay

Intake Shutter

Valve Position

Vehicle SpeedSensor

A/C Switch

Immobilizer

SEC-E

Instrument

Cluster

M

M

Brake Switch 1

FPLSWDPF LAMP

11

Fuel Temperature Sensor

10

SCV-

SCV(Suction Control Valve)

SCV+

THF 50

THFRTN 69

Coolant Temperature Sensor51

THWRTN

THW

70

29

Q001555E

Rail Pressure Sensor

(Pc Sensor)

EXTAir Temperature Sensor

Airflow Sensor

P1

Turbo Pressure Sensor

COMMON104

TWV143

TWV142

COMMON105

TWV2

TWV2

24

Injector 3 Drive (#4 Cylinder)

23

TWV341

TWV340

TWV422

TWV421

P-GND

Body Earth

P-GND

C-GND

01

02

P-GND03

114

48PFUEL1

49

63

PFUEL2

A-VCC5

68PFUELRTN

64

52BOOST

71BOOST RTN

A-VCC6

55

74

54AMF

73AMF RTN

Neutral Switch

Power Steering Switch

110N-SW

111PSSW

EXT-A-TMP

EXT-A-RTNInjector 4 Drive (#2 Cylinder)



Body Ground

12

6.2. ENGINE ECU CONNECTOR TERMINAL LAYOUTEngine ECU connector terminals are as per below.

(1) Without DPF System (275800 - 445#, -453# -454#, -455#, -456#, -458#)

(2) With DPF System (275800 - 444#, -450#, -451#, -452#)

No. Pin Symbol Connections No. Pin Symbol Connections

1 P-GND Power Ground 13 - -

2 P-GND Power Ground 14 FPLSW Fuel Level Switch

3 P-GND Power Ground 15 RFRL RFRL

4 COMMON1 Injection Common 16 RFRM RFRM

5 COMMON1 Injection Common 17 EMNT EMNT

6 VNTEVRV (Electronic-Vacuum Regulation valve) FOR VNT

18 DPF LMP DPF Light

7 - - 19 - -

8 - - 20 ACRLY Air Conditioner Relay

9 - - 21 TWV4 Injection Drive 4

10 SCV+ SCV (Suction Control Valve) 22 TWV4 Injection Drive 4



RFRE RFRM RFRL

BRK2 STRGSTRGRTN

IM

PDPSNS

PD-P-RTN

FPLSWACRLY

GLOWRLY

DPFTMP2

DPFTMP2RTN

Q001552E

RFRE RFRM RFRL

AFHTAFHTGND BRK2 STRG

ISVPAFRTN

AF

STRGRTN

ISV-

ISV+

IM

PDPSNSPD-P-RTN

FPLSWACRLY

FPR GLOWRLY

DPFPSNS DPFTMP2

DPF-P-TMP

DPFTMP2RTN

DPFTMP1

DPFTMP1RTN

Q001553E

13

No. Pin Symbol Connections No. Pin Symbol Connections

25 EGR#1 Step Motor A 51 THW Coolant Temperature Sensor

26 EGR#2 Step Motor B’ 52 BOOST Boost Pressure Sensor

27 EGR#3 Step Motor A’ 53 PD PSNS Refrigerant Pressure Sensor

28 EGR#4 Step Motor B 54 AMF Mass Air Flow Sensor29 SCV- SCV 55 EXT-A-TMP EXT-Air Temperature

30 - - 56 DPF TMP1 Exhaust Gas Temperature Sensor

31 - - 57 DPF TMP2 Exhaust Gas Temperature Sensor

32 - - 58 DPF PSNS Differential Pressure Sensor

33 - - 59 - -34 AFHT A/F Heater 60 - -35 AFHTGND A/F Heater GND 61 - -36 - - 62 - -37 GLOWRLY Glow Relay 63 A-VCC5 Sensor (Power Supply)38 - - 64 A-VCC6 Sensor (Power Supply)

39 FPR Fuel Pump Relay 65 NE- Crankshaft Position Sensor -

40 TWV3 Injection Drive 3 66 G- Cylinder Recognition Sensor -

41 TWV3 Injection Drive 3 67 S-GND Shield Ground42 TWV1 Injection Drive 1 68 PFUELRTN Sensor Ground

43 TWV1 Injection Drive 1 69 THFRTN Fuel Temperature Sensor RTN

44 - - 70 THWRTN Coolant Temperature Sensor RTN

45 A-VCC4 Sensor (Power Supply) 71 BOOSTRTN Boost Pressure Sensor RTN

46 NE+ Crankshaft Position Sensor + 72 PD-P-TMP Refrigerant Pressure

Sensor RTN

47 G+ Cylinder Recognition Sensor + 73 AMFRTN Mass Air Flow Sensor

48 PFUEL Rail Pressure Sensor 74 EXT-A-RTN EXT-Air Temperature Sensor RTN

49 PFUEL Rail Pressure Sensor 75 DPF TMP1 RTN

Exhaust Gas Temperature 1 RTN

50 THF Fuel Temperature Sensor 76 DPF TMP2 RTN

Exhaust Gas Temperature 2 RTN

14

No. Pin Symbol Connections No. Pin Symbol Connections77 - - 100 BRK1 Brake Switch 1

78 - - 101 BRK2 Brake Switch 2

79 DPF-P-TMP Exhaust Pressure Temperature Sensor 102 STRG Steering Switch

80 - - 103 STRGRTN Steering Switch RTN

81 - - 104 - -

82 A-VCC1 Sensor (Power Supply) 105 M-REL Main Relay

83 APS1 Accelerator Position Sensor 106 - -

84 APS1GND Accelerator Pedal Sensor Ground 107 IG-SW Ignition Switch

85 AFRTN A/F Sensor RTN 108 IG-SW Ignition Switch

86 ISVP ISV Position Sensor 109 - -

87 CAN1-L CAN Communication 110 N-SW Neutral Switch

88 - - 111 PS-SW Power Steering Switch

89 K-LINE KWP2000 K-Line 112 IM Immobilizer

90 A-VCC2 Sensor (Power Supply) 113 M-REL Main Relay

91 APS2 Accelerator Position Sensor 114 C-GND Signal Ground

92 APS2GND Accelerator Position Sensor Ground 115 - -

93 AF A/F Sensor 116 ISV+ Intake Shutter+

94 - - 117 - -

95 CAN1-H CAN Communication 118 ISV- Intake Shutter-

96 - - 119 +BP Battery + (Main Relay)

97 - - 120 +BP Battery + (Main Relay)

98 - - 121 BATT Battery +

99 STA-SW Starter Switch - - -

denso cr - hp3 nissan

Documents

detection item description

glow plug circuit

suction control valve

vehicle speed sensor

common rail system

adjustable resistance correction

exhaust gas temperature

engine ecu detects