agdosoftware mecatrônica treinamento toyota hilux.pdf
Transcript of 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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Model Outline KD Series Engine Chassis Body Body Electrical
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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Model Outline KD Series Engine Chassis Body Body Electrical
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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Model Outline KD Series Engine Chassis Body Body Electrical
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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Model Outline KD Series Engine Chassis Body Body Electrical
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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Model Outline KD Series Engine Chassis Body Body Electrical
Engine Overall
Features– Under floor Fuel Cooler
(with intercooler model only)
Front
d l l h d d El l
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Model Outline KD Series Engine Chassis Body Body Electrical
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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Model Outline KD Series Engine Chassis Body Body Electrical
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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Model Outline KD Series Engine Chassis Body Body Electrical
Lubrication System
Lubrication System– Overall
• Lubrication is fully pressurized and all oil passesthrough an oil cooler and oil filter
Oil Cooler
Oil Filter
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Model Outline KD Series Engine Chassis Body Body Electrical
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
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intake Shutter Valve– Construction
Hall IC
Magnet
Magnet
Steel Layer
Magnet
Intake Shutter ValvePosition Sensor
Rotary SolenoidType Motor
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intake Manifold– Two intake port with different shape from intake
manifold to cylinder head• For swirl optimizing in cylinder
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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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Model Outline KD Series Engine Chassis Body Body Electrical
At low engine speed,SCV is closed to
strengthen the swirl
Intake and Exhaust System
Swirl Control Valve (1KD only)– Operation
Actuator
Intake Air
VSV
VacuumPump
EngineECU
AcceleratorPedal Opening
Engine Speed
ON / OFF
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)– Operation movie
Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Turbocharger (2KD only)– Light weight, compact and high performance
turbocharger
Waste GateValve
Actuatorfor WasteGate Valve
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intercooler– Intake air is cooled in intercooler to increase the air
density
Turbocharger
ThermalExpansion ContractionIncrease
oxygen densityOxygen
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Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intercooler– Intake air is cooled in intercooler to increase the air
density
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Model Outline KD Series Engine Chassis Body Body Electrical
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
Fuel SystemWarning Light
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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Common-rail System
Supply Pump– Construction
Ring Cam
Plunger
EccentricCam
To fuel tank(return)
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Common-rail System
Supply Pump– Fuel flow
From fueltank
To common-rail
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Common-rail System
Supply Pump– Fuel flow (reference)
Click!
Movie
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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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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
Model Outline KD Series Engine Chassis Body Body Electrical
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Common-rail System
Injector– High pressure injection for higher atomization
InjectorCompensation
CodeFromCommon-rail
Return toFuel Tank
0.14 mm
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Common-rail System
Injector– Construction
NozzleNeedle
Piston
Solenoid Coil
Return toFuel Tank
FromCommon-rail
NozzleSpring
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Common-rail System
Injector– Controlled by engine ECU signal
SolenoidSolenoid
TWV
Return
FromCommon-rail Large
Orifice
Small
Orifice
Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
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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
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Common-rail System
Injector– Pilot injection reduces NOx and engine noise
Model Outline KD Series Engine Chassis Body Body Electrical
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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
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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
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Common rail S stem
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Common-rail System
Diagnosis– DTCs for common-rail system
DTC No. Detection Item Detection Condition
P0087(49)
Fuel Rail/SystemPressure - Too Low
Fuel pressure sensor output voltage staysat fixed value
P0088(78)
Fuel Rail/SystemPressure - Too High
Fuel pressure exceeds predeterminedvalue
P0093(78)
Fuel System LeakDetected - Large Leak
Difference of common-rail pressure beforeand after fuel injection varies greatly fromdifference of value that engine ECUcalculates before and after injection
P0190(49)
Fuel Rail Pressure SensorCircuit Malfunction
Fuel pressure sensor output voltage is0.55V or less, or 4.9V or more for 0.5 sec.
P0192(49)
Fuel Rail Pressure SensorCircuit Low Input
Fuel pressure sensor output voltage is0.55V or less for 0.5 sec.
P0193(49)
Fuel Rail Pressure SensorCircuit High Input
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
Model Outline KD Series Engine Chassis Body Body Electrical
Common rail System
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Common-rail System
Diagnosis– DTCs for common-rail system
DTC No. Detection Item Fail-safe
P0087(49)
Fuel Rail/SystemPressure - Too Low
Limits engine powerP0088(78)
Fuel Rail/SystemPressure - Too High
P0093(78)
Fuel System LeakDetected - Large Leak
Limits engine power for 1 min., and thenstops the engine
P0190(49)
Fuel Rail Pressure SensorCircuit Malfunction
Limits engine powerP0192(49)
Fuel Rail Pressure SensorCircuit Low Input
P0193(49)
Fuel Rail Pressure SensorCircuit High Input
Trouble Area Fail-safeDetection Condition
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Common rail System
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Common-rail System
Diagnosis– DTCs for 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
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Common rail System
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Common-rail System
Diagnosis– DTCs for common-rail system
DTC No. Detection Item Detection Condition
P0200(97)
Injector Circuit / Open
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)
Fuel Pump Control Circuit / Open
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 CorrectionCircuit Malfunction(EEPROM)
Injector compensation code is notregistered
1 trip detection logic for all DTC
Detection ConditionTrouble Area Fail-safe
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Common rail System
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Common-rail System
Diagnosis– DTCs for common-rail system
DTC No. Detection Item Fail-safe
P0200(97)
Injector Circuit / Open
Limits engine powerP0627(78)
Fuel Pump Control Circuit / Open
P1229(78)
Fuel Pump System
P1601(89)
Injector CorrectionCircuit Malfunction(EEPROM)
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Fail-safeDetection ConditionTrouble Area
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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
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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
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Fuel System
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Fuel System
Fuel Filter– Construction
Filter Element
Fuel FilterWarning Switch
From Fuel Tank To Supply Pump
PrimingPump
Fuel Sedimenter LevelWarning Switch
Filter Housing(Plastic)
Fastener Nut
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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
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
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Fuel System
Fuel Warning System– System Diagram
Combination Meter
Fuel FilterWarning Switch
MeterECU
Filter Element
Fuel SystemWarning Light
To Supply Pump
Vehicle SpeedSensor
Fuel Sedimenter Level Warning SwitchFuel Filter
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
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Engine Control System
Oil Maintenance Management System– This system determines the deterioration conditions of
the engine oil
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
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Engine Control System
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
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
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Engine Control System
Oil Maintenance Management System– Soot calculating logic
A/F Ratio
InjectionEnd Timing
SootVolume
Rich
Lean
Retard
Advance
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
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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
Model Outline KD Series Engine Chassis Body Body Electrical
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Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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
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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
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Fuel Cooler– Construction
From
Supply Pump / InjectorTo Fuel Tank
CrossSection
Fin
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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