agdosoftware mecatrônica treinamento toyota hilux.pdf

8/18/2019 agdosoftware mecatrônica treinamento toyota hilux.pdf

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Model Outline KD Series Engine Chassis Body Body Electrical

Contents

Click a Section Tab


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Engine Overall Engine Proper Valve Mechanism Lubrication System

Intake and Exhaust System Common-rail System Fuel System Charging SystemSerpentine Belt Drive System Engine Control System


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Engine Overall

1KD-FTV / 2KD-FTV– TOYOTA D-4D, 3.0 / 2.5 liter, in-line 4-cylinder,

16 valve DOHC with turbocharged diesel engine

1KD-FTV 2KD-FTV


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Engine Overall

1KD-FTV / 2KD-FTV Specifications

Item

1KD-FTV

(HILUX,FORTUNER)

2KD-FTV

(HILUX, FORTUNER,INNOVA)

No. of Cylinders & Arrangement 4-Cylinder, In-line

Valve Mechanism16-Valve DOHC,Belt & Gear Drive

Fuel System Common-Rail Type

Intercooler With Without / With *2

Displacement cm3 (cu. in.) 2,982 (182.0) 2,492 (152.2)

Bore x Strokemm (in.)

96.0 x 103.0(3.78 x 4.06)

92.0 x 93.8(3.62 x 3.69)

Compression Ratio 18.4 18.5

Max. OutputkW @ rpm

120 @ 3,40075 @ 3,600

88 @ 3,600 *2

Max. TorqueN·m @ rpm

343 @1,400 ~3,200

200 @ 1,400 ~ 3,200260 @ 1,600 ~ 2,400 *1

320 @ 2,000 *2

*1: 2KD-FTV High Version*2: 2KD-FTV High Version (HILUX for Thai only)


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Engine Overall

Features– Engine compartment

Fuel Filter•Fuel filter warning (clogging detection)

•Element replacing typeSLLC

Rotary Solenoid TypeDiesel ThrottleVN Type Turbocharger(1KD only)

Photo: 1KD-FTV


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Engine Overall

Features– Under floor Fuel Cooler

(with intercooler model only)

Front

d l l h d d El l


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Engine Proper

Piston– In conjunction with the adoption of direct injection,

combustion chamber is provided on piston

CombustionChamber

Ni-resistCast Iron

Ring Carrier

CoolingChannel

1KD-FTV 2KD-FTV

SIRMRing

Carrier

M d l O li D E Ch i B d B d El i l


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Valve Mechanism

Timing Belt– Maintenance interval: replace at every 150,000 km

TimingBelt

Automatic

BeltTensioner

CamshaftTiming

Pulley No. 2

CamshaftTiming

Pulley No. 1

Oil Pump Drive Gear

Crankshaft Timing Gear

Supply Pump Drive Gear

Idle Gear

Vacuum Pump Drive Gear

M d l O tli KD S i E i Ch i B d B d El i l


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Lubrication System

Lubrication System– Overall

• Lubrication is fully pressurized and all oil passesthrough an oil cooler and oil filter

Oil Cooler

Oil Filter

M d l O tli KD S i E i Ch i B d B d El t i l


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Intake and Exhaust System

Intake Shutter Valve– Rotary solenoid type intake shutter valve is used to

improve EGR performanceEngine

ConditionValve

PositionPurpose

StartingFull

OpenReduced DieselSmoke

Running Small -FullOpen

Controls EGRamount

StopFull

CloseReduced noiseand vibration

Rotary Solenoid type Motor

Intake Shutter ValvePosition Sensor

Intake Shutter Valve

Air flow

M d l O tli KD S i E i Ch i B d B d El t i l


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Intake Shutter Valve– Construction

Hall IC

Magnet

Magnet

Steel Layer

Magnet

Intake Shutter ValvePosition Sensor

Rotary SolenoidType Motor

M d l O tli KD S i E i Ch ssis B d B d El t i l


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Intake Manifold– Two intake port with different shape from intake

manifold to cylinder head• For swirl optimizing in cylinder

Model Outline KD S ri s En in Ch ssis B d B d El ctric l


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Swirl Control Valve (1KD only)– Swirl control valve is provided to realize clean

emission

Swirl Control Valve

Intake Manifold

Actuator

VSV for SCV

1KD-FTV only



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At low engine speed,SCV is closed to

strengthen the swirl


Swirl Control Valve (1KD only)– Operation

Actuator

Intake Air

VSV

VacuumPump

EngineECU

AcceleratorPedal Opening

Engine Speed

ON / OFF



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Variable Nozzle Vane Type Turbocharger (1KD only)– Nozzle Vane is driven by DC motor

DC Motor

Link

TurbineWheel

Full-

CloseStopper

Motor Rod

Nozzle VanePosition Sensor



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Variable Nozzle Vane Type Turbocharger (1KD only)– Construction

DC Motor

Link

Nozzle Vane

TurbineWheel

Motor Rod

Nozzle VanePosition Sensor

Full-

CloseStopper

Intake Air

ReductionGears

ExhaustGas



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Variable Nozzle Vane Type Turbocharger (1KD only)– Construction

Drive Arm

Unison Ring

Driven Arm

TurbineWheel

Full-Close Stopper

Link

Motor Rod

NozzleVane

Gas Flow



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Variable Nozzle Vane Type Turbocharger (1KD only)– Feedback Control

Nozzle

VanePosition

Turbo MotorDriver

Target Angle

Control StatusEngineECU

Turbo Pressure

Sensor

AtmosphericTemp. Sensor

AtmosphericPressureSensor

Water Temp.Sensor

Injector (EDU)

CrankshaftPosition Sensor

DCMotor

Nozzle

VanePositionSensor

Control



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Variable Nozzle Vane Type Turbocharger (1KD only)– Zero point calibration

IGOFF ON

IGON OFF

After theenginestart

Close

Open

Motor Rod

Full-Close

Stopper

0

Link

0

Link is bumpedto full-close

stopper

Zero pointcalibration

Nozzle vane iscontrolled basedon the zero point



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Variable Nozzle Vane Type Turbocharger (1KD only)– Operation movie

Click!

Movie



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Turbocharger (2KD only)– Light weight, compact and high performance

turbocharger

Waste GateValve

Actuatorfor WasteGate Valve



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Intercooler– Intake air is cooled in intercooler to increase the air

density

Turbocharger

ThermalExpansion ContractionIncrease

oxygen densityOxygen



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Intercooler– Intake air is cooled in intercooler to increase the air

density



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Fuel System

General

Fuel PressureSensor

EDU

PressureLimiter

Supply Pump

SCV

Engine

ECU

Fuel Tank

Injector

NE Signal

G Signal

VariousSignals

Common-rail

Fuel Cooler

PressureSwitch

FuelFilter

Fuel SystemWarning Light

Other Injectors



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Model Outline KD E g Chassis Body Body Electrical

Fuel System

Features

Fuel PressureSensor

EDU

PressureLimiter

Supply Pump

SCV

Engine

ECU

Fuel Tank

Injector

NE Signal

G Signal

VariousSignals

Common-rail

Fuel Cooler

PressureSwitch

FuelFilter


Other Injectors

Max. 160MPa

HP3 TypeSupply

Pump

Warning lightfor fuel filterclogging and

fuel sedimenter

Injectorcompensation

code

Elementreplacement

type

Detectsfilter

clogging

Fuel coolercools return

fuel



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Model Outline g Chassis Body Body Electrical

Common-rail System

General– This system realize high injection pressure in all speed

range of the engine

Fuel PressureSensor

PressureLimiter

EngineECU

Fuel Tank

NE Signal

G Signal

VariousSignals

SCVSupply Pump

(Generates high-pressure fuel)

Common-rail

Injector(Injects high-pressure fuel)

EDU(Operates injector

at high-speed)

: High-pressure (Max. 160 MPa)

(Stores high-pressure fuel)



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Model Outline g Chassis Body Body Electrical

Common-rail System

System Outline

System

Common-rail Diesel Conventional Diesel

Injection VolumeControl

ECU (Injector) Pump (Governor)

Injection TimingControl ECU (Injector) Pump (Timer)

Injection PressureControl

Supply Pump (SCV)According to rotational speed

and injection quantity

Pressurization Supply Pump Pump

Distribution Common-rail Pump

Injection Pressure Max. 160 MPa Approx. 15 MPa

PressureSensor

Constant high pressure

ECU

SCV

Supply Pump

Common-rail

Injector

Instantaneously high pressure

TimerGovernor

PumpInjectionNozzle



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M u n g a y y E r a

Common-rail System

Location

Common-rail•Fuel Pressure Sensor

•Pressure LimiterSupply Pump•SCV (Suction Control Valve)

•Fuel Temp. Sensor

Injector

EngineFront

Injection Pipe

Fuel Inlet Pipe



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g y y

Common-rail System

Supply Pump– Supplies the high pressure fuel to the common-rail

– Driven by crankshaft

From Fuel Filter(Inlet)

To Common-rail(Outlet)

To Fuel Tank(Return)

SCV(Suction Control Valve)



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g y y

Common-rail System

Supply Pump– Construction

PlungerFeedPump

DeliveryValve

SCV (Suction

Control Valve)

FuelTemp.Sensor

CheckValve

Eccentric andRing Cam



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g y y

Common-rail System

Supply Pump– Construction

Ring Cam

Plunger

EccentricCam

To fuel tank(return)



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y y

Common-rail System

Supply Pump– Fuel flow

From fueltank

To common-rail



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y y

Common-rail System

Supply Pump– Fuel flow (reference)

Click!

Movie



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y y

Common-rail System

Supply Pump– Suction and pumping operation

SCV

: From Feed Pump : To Common-rail

Plunger A: SuctionPlunger B: Pumping

Plunger A: Pumping Plunger B: Suction

Plunger A

Plunger B

CheckValve



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y y

Common-rail System

Supply Pump– Suction and pumping operation

Click!

Movie



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Common-rail System

Supply Pump– Fuel control operation (SCV opening small)

Fuel

PumpingMass



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Common-rail System

Supply Pump– Fuel control operation (SCV opening large)

FuelPumping

Mass



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Common-rail System

Supply Pump– Fuel control operation (SCV opening small)

Click!

Movie



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Common-rail System

Supply Pump– Fuel control operation (SCV opening large)

Click!

Movie



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Common-rail System

Supply Pump– The SCV opening regulates the pumping volume to

control fuel pressure

Controls

SCVopening

Common-rail pressure(Feedback)

Accelerator PedalPosition Sensor

SCV

Fuel PressureSensor

Crankshaft

Position Sensor

Engine ECU

Calculation oftarget injection

pressure

[Fuel Pressure Control]



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Common-rail System

Common-rail– Stores high-pressure fuel (Max. 160 MPa) produced by

supply pump

FromSupply Pump

To Injector To Fuel Tank

Fuel

PressureSensor

PressureLimiter

Common-rail



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Common-rail System

Common-rail– Fuel pressure sensor

• Detects the internal fuel pressure of common-rail

Common-railPressure

0 190

1.0

4.04

Common-rail Pressure (MPa)

O

u t p u t V o l t a g e ( V )

Output characteristicSensor Tip

90

2.44


C S


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Common-rail System

Injector– High pressure injection for higher atomization

InjectorCompensation

CodeFromCommon-rail

Return toFuel Tank

0.14 mm


C il S t


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Common-rail System

Injector– Construction

NozzleNeedle

Piston

Solenoid Coil

Return toFuel Tank

FromCommon-rail

NozzleSpring


C il S t


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Common-rail System

Injector– Controlled by engine ECU signal

SolenoidSolenoid

TWV

Return

FromCommon-rail Large

Orifice

Small

Orifice

Click!

Movie


C il S t


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Common-rail System

Injector– Pilot injection reduces NOx and engine noise

TDCTDC

PilotInjection Control

ConventionalInjection Control

Pilot

Main

HeatReleaseValue

InjectionVolume

NOx and

engine noise


C il S t


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Common-rail System

Injector– Pilot injection reduces NOx and engine noise


C il S t


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Common-rail System

EDU (Electronic Driver Unit)– Drive the injectors at high speed

EngineECU

EDU

Injector

HighVoltageDC / DC

Converter

CommandPulse

ConfirmationPulse

Battery

IJT#1-4

IJF

ControlCircuit High-speed

operation


C il S t


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Fail-safeDetection Condition

Common-rail System

Diagnosis– DTCs for common-rail system

DTC No. Detection Item Trouble Area

P0087(49)

Fuel Rail/SystemPressure - Too Low

•Open or short in fuel pressure sensorcircuit •Fuel pressure sensor •Engine ECU

P0088(78)

Fuel Rail/SystemPressure - Too High

•Short in supply pump (SCV) circuit•Supply pump (SCV) •Engine ECU

P0093(78)

Fuel System LeakDetected - Large Leak

•High pressure fuel line•Open or short in EDU circuit•Open or short in injector circuit•Supply pump •Common-rail •Injectors•EDU •Engine ECU

P0190(49)

Fuel Rail Pressure SensorCircuit Malfunction

• Open or short in fuel pressure sensorcircuit

•Fuel pressure sensor•Engine ECU

P0192(49)

Fuel Rail Pressure SensorCircuit Low Input

P0193(49)

Fuel Rail Pressure SensorCircuit High Input

Trouble Area


Common rail S stem


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Common-rail System


DTC No. Detection Item Detection Condition

P0087(49)


Fuel pressure sensor output voltage staysat fixed value

P0088(78)


Fuel pressure exceeds predeterminedvalue

P0093(78)


Difference of common-rail pressure beforeand after fuel injection varies greatly fromdifference of value that engine ECUcalculates before and after injection

P0190(49)


Fuel pressure sensor output voltage is0.55V or less, or 4.9V or more for 0.5 sec.

P0192(49)


Fuel pressure sensor output voltage is0.55V or less for 0.5 sec.

P0193(49)


Fuel pressure sensor output voltage is4.9V or more for 0.5 sec.

1 trip detection logic for all DTC

Detection Condition Fail-safeTrouble Area


Common rail System


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Common-rail System


DTC No. Detection Item Fail-safe

P0087(49)


Limits engine powerP0088(78)


P0093(78)


Limits engine power for 1 min., and thenstops the engine

P0190(49)




P0193(49)


Trouble Area Fail-safeDetection Condition


Common rail System


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Common-rail System


DTC No. Detection Item Trouble Area

P0200(97)

Injector Circuit / Open

•Open or short in EDU circuit •EDU •Injector

•Engine ECU

P0627(78)

Fuel Pump Control Circuit / Open

•Open or short in (SCV) circuit •SCV •Engine ECU

P1229(78)

Fuel Pump System•Short in supply pump (SCV) circuit •Supply pump (SCV) •Engine ECU

P1601(89)

Injector CorrectionCircuit Malfunction(EEPROM)

•Injector compensation code •Engine ECU

Fail-safeTrouble Area Detection Condition


Common rail System


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Common-rail System


DTC No. Detection Item Detection Condition

P0200(97)


Open or short in EDU or injector circuit.After engine is started, there is noinjection confirmation (IJF) signal fromEDU, despite engine ECU sending

injection command (IJT) signal to EDU

P0627(78)


Open or short in suction control valvecircuit for more than 0.5 sec.

P1229(78)

Fuel Pump System

Fuel over-feed:

Fuel pressure continues exceeding targetfuel pressure despite engine ECU closingSCV

P1601(89)


Injector compensation code is notregistered

1 trip detection logic for all DTC

Detection ConditionTrouble Area Fail-safe


Common rail System


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Common-rail System


DTC No. Detection Item Fail-safe

P0200(97)




P1229(78)

Fuel Pump System

P1601(89)


-

Fail-safeDetection ConditionTrouble Area


Common rail System


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Common-rail System

Service Point for Common-rail System– Supply pump initialization and calibration

– Common-rail replacement– Reprogramming of injector compensation code– Replace a new parts– Replace a new pipe– Check fuel leak (Leakage Pipe No.1 / Fuel System)

– Power Balance Check


Fuel System


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Fuel System

Fuel Filter– Replace fuel filter element only

Fuel FilterWarning Switch

From Fuel TankTo Supply Pump

PrimingPump

Filter Housing(Plastic)

Fastener Nut

Drain Cock

Filter Element


Fuel System


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Fuel System

Fuel Filter– Construction

Filter Element


From Fuel Tank To Supply Pump

PrimingPump

Fuel Sedimenter LevelWarning Switch

Filter Housing(Plastic)

Fastener Nut


Fuel System


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Fuel System

Fuel Warning System– Fuel filter clogging is detected by fuel filter warning

switch

Combination Meter

Fuel FilterWarning Switch Fuel System

Warning Light

Fuel Filter

- Fuel Filter Maintenance Interval -

Fuel system warning light has been illuminated

Clogging


Fuel System


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Fuel System

Fuel Warning System– System Diagram

Combination Meter


MeterECU

Filter Element


To Supply Pump

Vehicle SpeedSensor

Fuel Sedimenter Level Warning SwitchFuel Filter


Fuel System


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Fuel System

Fuel Warning System– Fuel filter warning switch turns OFF when the filter

outlet pressure decreasesFuel FilterWarningSwitch

To Supply Pump

Filter Element

Normal Fuel Filter(Switch: ON)

Fuel Filter Clogged Up(Switch: OFF)

Diaphragm

ON MeterECU

Fuel FilterWarningSwitch

To Supply Pump

OFF MeterECU

NegativePressure


Fuel System


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Fuel System

Fuel Warning System– Warning light condition for fuel filter / fuel sedimenter

WarningWarningMethod

Priority

SedimenterWarning

Blink

1

Fuel FilterWarning

ON

2


Fuel System


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Fuel System

Fuel Warning System– Detection conditions

OFF for 10 min.or more

OFF is detected for 2times during 1 trip

After the driving for 30 min. or more

The warning light keeps ON until the reset operation is done

Fuel Filter Warning Switch Condition

or


Charging System


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Charging System

Alternator Pulley• In order to absorb a engine fluctuation, one-way

clutch was adopted in the pulley

RollerSpring


Charging System


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Charging System

Alternator Pulley– Engine fluctuation absorbing mechanism

EngineFluctuation

AlternatorPulley Speed

Crankshaft PulleySpeed

P u l l e y S p e e d ( r p

m )

Time

One-wayClutch

Locked

One-wayClutch

Free


Serpentine Belt Drive System


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Serpentine Belt Drive System

Serpentine Belt Drive– Single V-ribbed belt

Alternator Pulleywith Shock

Absorbing Function

Water PumpPulley

Air ConditionerCompressor Pulley

Idler Pulley forAutomatic Tensioner

Idler Pulley

Idler Pulley

Crankshaft Pulley


Engine Control System


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Oil Maintenance Management System– This system determines the deterioration conditions of

the engine oil




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Oil Maintenance Management System– System diagram and general operation

SootVolume ODO / TRIP

Switch

Engine ECUEngine Oil Change

Reminder Light

•Engine Speed•Injection Volume•Injection Timing•A/F Ratio

Meter ECU

VehicleSpeed

Blink or ON

Soot VolumeCalculation




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Oil Maintenance Management System– Soot calculating logic

A/F Ratio

InjectionEnd Timing

SootVolume

Rich

Lean

Retard

Advance




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g y

Oil Maintenance Management System– Engine oil change reminder light operation

ConditionEngine Oil Change

Reminder Light

Mileage = 35,000 km ~ 40,000 kmor

Specified Soot Volume A

Mileage = 40,000 km or moreor

Specified Soot Volume B



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Reference


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Intake Shutter Valve– Intake shutter valve position sensor

Intake Shutter ValveOpening Angle (°)

O u t p u t V o l t a g e ( V )

0

EngineECU

VC

VLU

Hall IC

Magnet

E20

(Full Close)

70

(Full Open)

Intake ShutterValve Position

Sensor

1

5

0.71

20 100

3.51


Reference


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Variable Nozzle Vane Type Turbocharger (1KD only)– Nozzle Vane Position Sensor

• Non-contact type position sensor

0-55 55

0.5

2.5

4.5

Sensor shaft rotation angle ()

O

u t p u t V o l t a g e (

V )

Output characteristic ofmain, sub sensor

-55 55

Hall ICs

Magnets

Cross-section

0

Model Outline KD Series Engine Chassis Body Body Electrical Reference


73/76

Fuel Cooler– A fuel cooler cools the return fuel– It is used on the model equipped with an intercooler

From SupplyPump / Injector

To Fuel Tank

Fuel Cooler(Aluminum)

Front



74/76

Fuel Cooler– Construction

From

Supply Pump / InjectorTo Fuel Tank

CrossSection

Fin



75/76

Accelerator Pedal– Non-contact type accelerator pedal position sensor is

used

Accelerator PedalPosition Sensor



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Accelerator Pedal– Using magnet and hall IC

Accelerator Pedal Depressed Angle

Full OpenFull Close

VPA1

VPA2

O u t p u t V o l t a g e ( V )

0

5

VCP1

VCP2

VPA2

VPA1

HallIC

Magnets

EP1

EP2

EngineECU

AcceleratorPedal Position

Sensor

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