Mesin Diesel Toyota tipe 2 KD FTV 14

Model Outline KD Series Engine Chassis Body Body Electrical

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Model Outline KD Series Engine Chassis Body Body ElectricalEngine OverallEngine ProperValve MechanismLubrication System Intake and Exhaust SystemCommon-rail SystemFuel SystemCharging SystemSerpentine Belt Drive SystemEngine Control System


Engine Overall1KD-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


Engine Overall1KD-FTV / 2KD-FTV Specifications

Item1KD-FTV(HILUX,

FORTUNER)

2KD-FTV(HILUX, FORTUNER,

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

Valve Mechanism 16-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 Stroke

mm (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 18.5Max. Output

kW @ rpm 120 @ 3,400 75 @ 3,60088 @ 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)


Engine OverallFeatures– Engine compartment

Fuel Filter•Fuel filter warning (clogging detection)

•Element replacing typeSLLC

Rotary Solenoid Type Diesel ThrottleVN Type Turbocharger

(1KD only)

Photo: 1KD-FTV


Engine OverallFeatures– Under floor Fuel Cooler

(with intercooler model only)

Front


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

Timing Belt

Automatic Belt

Tensioner

Camshaft Timing

Pulley No. 2

Camshaft Timing

Pulley No. 1

Oil Pump Drive Gear

Crankshaft Timing Gear

Supply Pump Drive Gear

Idle Gear

Vacuum Pump Drive Gear


Lubrication SystemLubrication System– Overall

• Lubrication is fully pressurized and all oil passes through an oil cooler and oil filter

Oil Cooler

Oil Filter


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

improve EGR performanceEngine

ConditionValve

Position Purpose

Starting Full Open

Reduced Diesel Smoke

RunningSmall -

Full Open

Controls EGR amount

Stop Full Close

Reduced noise and vibration

Rotary Solenoid type Motor

Intake Shutter Valve Position Sensor

Intake Shutter Valve

Air flow


Intake and Exhaust SystemIntake Shutter Valve– Construction

Hall IC

Magnet

MagnetSteel Layer

Magnet

Intake Shutter Valve Position Sensor

Rotary Solenoid Type Motor


Intake and Exhaust SystemIntake Manifold– Two intake port with different shape from intake

manifold to cylinder head• For swirl optimizing in cylinder


Intake and Exhaust SystemSwirl 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


At low engine speed, SCV is closed to

strengthen the swirl

Intake and Exhaust SystemSwirl Control Valve (1KD only)– Operation

Actuator

Intake Air

VSV

Vacuum Pump

Engine ECU

Accelerator Pedal Opening

Engine Speed

ON / OFF


Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Nozzle Vane is driven by DC motor

DC Motor

Link

Turbine Wheel

Full-Close

Stopper

Motor Rod

Nozzle Vane Position Sensor


Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Construction

DC Motor

LinkNozzle Vane

Turbine Wheel

Motor Rod

Nozzle Vane Position Sensor

Full-Close

Stopper

Intake Air

Reduction Gears

Exhaust Gas


Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Construction

Drive Arm

Unison Ring

Driven Arm

Turbine Wheel

Full-Close Stopper

Link

Motor Rod

Nozzle Vane

Gas Flow


Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Feedback Control

Nozzle Vane

Position

Turbo Motor Driver

Target Angle

Control StatusEngineECUTurbo Pressure

Sensor

Atmospheric Temp. Sensor Atmospheric

Pressure Sensor

Water Temp. Sensor

Injector (EDU)

Crankshaft Position Sensor

DC Motor

Nozzle Vane

Position Sensor

Control


Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Zero point calibration

IG OFF ON

IG ON OFF

After the engine start

Close

OpenMotor Rod

Full-Close Stopper

0Link

0

Link is bumped to full-close

stopper

Zero point calibration

Nozzle vane is controlled based on the zero point


Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Operation movie

Click!Movie


Intake and Exhaust SystemTurbocharger (2KD only)– Light weight, compact and high performance

turbocharger

Waste Gate Valve Actuator

for Waste Gate Valve


Intake and Exhaust SystemIntercooler– Intake air is cooled in intercooler to increase the air

density

Turbocharger

Thermal Expansion Contraction Increase

oxygen densityOxygen


Intake and Exhaust SystemIntercooler– Intake air is cooled in intercooler to increase the air

density


Fuel SystemGeneral

Fuel Pressure Sensor

EDU

Pressure Limiter

Supply PumpSCV

Engine ECU

Fuel Tank

Injector

NE SignalG SignalVarious Signals

Common-rail

Fuel Cooler

Pressure Switch

Fuel Filter

Fuel System Warning Light

Other Injectors


Fuel SystemFeatures


EDU

Pressure Limiter

Supply PumpSCV

Engine ECU

Fuel Tank

Injector


Common-rail

Fuel Cooler

Pressure Switch

Fuel Filter


Other Injectors

Max. 160MPaHP3 Type

Supply Pump

Warning light for fuel filter clogging and

fuel sedimenter

Injector compensation

code

Element replacement

typeDetects

filter clogging

Fuel cooler cools return

fuel


Common-rail SystemGeneral– This system realize high injection pressure in all speed

range of the engine


Pressure Limiter

Engine ECU

Fuel Tank


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)


Common-rail SystemSystem Outline

System

Common-rail Diesel Conventional Diesel

Injection Volume Control ECU (Injector) Pump (Governor)

Injection Timing Control ECU (Injector) Pump (Timer)

Injection Pressure Control Supply Pump (SCV) According to rotational speed

and injection quantityPressurization Supply Pump PumpDistribution Common-rail Pump

Injection Pressure Max. 160 MPa Approx. 15 MPa

Pressure Sensor

Constant high pressure

ECU

SCV

Supply Pump

Common-rail

Injector

Instantaneously high pressure

TimerGovernor

Pump Injection Nozzle


Common-rail SystemLocation

Common-rail•Fuel Pressure Sensor

•Pressure LimiterSupply Pump•SCV (Suction Control Valve)

•Fuel Temp. Sensor

Injector

Engine Front

Injection Pipe

Fuel Inlet Pipe


Common-rail SystemSupply 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)


Common-rail SystemSupply Pump– Construction

Plunger Feed Pump

Delivery Valve

SCV (Suction Control Valve)

Fuel Temp. Sensor

Check Valve

Eccentric and Ring Cam


Common-rail SystemSupply Pump– Construction

Ring Cam

Plunger

Eccentric Cam

To fuel tank (return)


Common-rail SystemSupply Pump– Fuel flow

From fuel tank

To common-rail


Common-rail SystemSupply Pump– Fuel flow (reference)

Click!Movie


Common-rail SystemSupply Pump– Suction and pumping operation

SCV

: From Feed Pump : To Common-rail

Plunger A: SuctionPlunger B: Pumping

Plunger A: PumpingPlunger B: Suction

Plunger A

Plunger B

Check Valve


Common-rail SystemSupply Pump– Suction and pumping operation

Click!Movie


Common-rail SystemSupply Pump– Fuel control operation (SCV opening small)

Fuel Pumping

Mass


Common-rail SystemSupply Pump– Fuel control operation (SCV opening large)

Fuel Pumping

Mass


Common-rail SystemSupply Pump– Fuel control operation (SCV opening small)

Click!Movie


Common-rail SystemSupply Pump– Fuel control operation (SCV opening large)

Click!Movie


Common-rail SystemSupply Pump– The SCV opening regulates the pumping volume to

control fuel pressure

Controls SCV

opening

Common-rail pressure

(Feedback)

Accelerator Pedal Position Sensor

SCV


Crankshaft Position Sensor

Engine ECU

Calculation of target injection

pressure

[Fuel Pressure Control]


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

supply pump

FromSupply Pump To Injector To Fuel Tank


Pressure Limiter

Common-rail


Common-rail SystemCommon-rail– Fuel pressure sensor

• Detects the internal fuel pressure of common-rail

Common-rail Pressure

0 190

1.0

4.04

Common-rail Pressure (MPa)

Outp

ut V

olta

ge (V

)

Output characteristic Sensor Tip

90

2.44


Common-rail SystemInjector– High pressure injection for higher atomization

Injector Compensation

CodeFromCommon-rail

Return toFuel Tank

0.14 mm


Common-rail SystemInjector– Construction

Nozzle Needle

Piston

Solenoid Coil

Return toFuel Tank

FromCommon-rail

Nozzle Spring


Common-rail SystemInjector– Controlled by engine ECU signal

SolenoidSolenoid

TWV

Return

From Common-rail Large

Orifice

Small Orifice

Click!Movie


Common-rail SystemInjector– Pilot injection reduces NOx and engine noise

TDCTDCPilot

Injection ControlConventional

Injection Control

PilotMain

Heat Release Value

Injection Volume

NOx and engine noise


Common-rail SystemInjector– Pilot injection reduces NOx and engine noise


Common-rail SystemEDU (Electronic Driver Unit)– Drive the injectors at high speed

Engine ECU

EDU

Injector

High VoltageDC / DC

Converter

Command Pulse

Confirmation Pulse

Battery

IJT #1-4

IJF

Control Circuit High-speed

operation


Fail-safeDetection Condition

Common-rail SystemDiagnosis– DTCs for common-rail system

DTC No. Detection Item Trouble AreaP0087 (49)

Fuel Rail/System Pressure - Too Low

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

P0088 (78)

Fuel Rail/System Pressure - Too High

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

P0093 (78)

Fuel System Leak Detected - 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 Sensor Circuit Malfunction • Open or short in fuel pressure sensor

circuit •Fuel pressure sensor •Engine ECU

P0192(49)

Fuel Rail Pressure Sensor Circuit Low Input

P0193(49)

Fuel Rail Pressure Sensor Circuit High Input

Trouble Area



DTC No. Detection Item Detection ConditionP0087 (49)

Fuel Rail/System Pressure - Too Low

Fuel pressure sensor output voltage stays at fixed value

P0088 (78)


Fuel pressure exceeds predetermined value

P0093 (78)


Difference of common-rail pressure before and after fuel injection varies greatly from difference of value that engine ECU calculates before and after injection

P0190 (49)

Fuel Rail Pressure Sensor Circuit Malfunction

Fuel pressure sensor output voltage is 0.55V or less, or 4.9V or more for 0.5 sec.

P0192(49)


Fuel pressure sensor output voltage is 0.55V or less for 0.5 sec.

P0193(49)


Fuel pressure sensor output voltage is 4.9V or more for 0.5 sec.

1 trip detection logic for all DTC

Detection Condition Fail-safeTrouble Area



DTC No. Detection Item Fail-safeP0087 (49)

Fuel Rail/System Pressure - Too Low Limits engine power

P0088 (78)


P0093 (78)


Limits engine power for 1 min., and then stops the engine

P0190 (49)

Fuel Rail Pressure Sensor Circuit Malfunction

Limits engine powerP0192(49)


P0193(49)


Trouble Area Fail-safeDetection Condition



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 Correction Circuit Malfunction (EEPROM)

•Injector compensation code•Engine ECU

Fail-safeTrouble Area Detection Condition



DTC No. Detection Item Detection Condition


Open or short in EDU or injector circuit.After engine is started, there is no injection confirmation (IJF) signal from EDU, despite engine ECU sending injection command (IJT) signal to EDU

P0627(78)


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


Fuel over-feed: Fuel pressure continues exceeding target fuel pressure despite engine ECU closing SCV

P1601 (89)

Injector Correction Circuit Malfunction (EEPROM)

Injector compensation code is not registered

1 trip detection logic for all DTC

Detection ConditionTrouble Area Fail-safe



DTC No. Detection Item Fail-safe


Limits engine powerP0627(78)



P1601 (89)

Injector Correction Circuit Malfunction (EEPROM) -

Fail-safeDetection ConditionTrouble Area


Common-rail SystemService 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 SystemFuel Filter– Replace fuel filter element only

Fuel Filter Warning Switch

From Fuel TankTo Supply Pump

Priming Pump

Filter Housing (Plastic)

Fastener Nut

Drain Cock

Filter Element


Fuel SystemFuel Filter– Construction

Filter Element


From Fuel Tank To Supply Pump

Priming Pump

Fuel Sedimenter Level Warning Switch

Filter Housing (Plastic)

Fastener Nut


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

switch

Combination Meter

Fuel Filter Warning Switch Fuel System

Warning Light

Fuel Filter

- Fuel Filter Maintenance Interval - Fuel system warning light has been illuminated

Clogging


Fuel SystemFuel Warning System– System Diagram

Combination Meter


Meter ECU

Filter Element


To Supply Pump

Vehicle Speed Sensor

Fuel Sedimenter Level Warning SwitchFuel Filter


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

outlet pressure decreasesFuel Filter Warning Switch

To Supply Pump

Filter Element

Normal Fuel Filter (Switch: ON)

Fuel Filter Clogged Up(Switch: OFF)

Diaphragm

ON Meter ECU


To Supply Pump

OFF Meter ECU

Negative Pressure


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

Warning Warning Method Priority

Sedimenter Warning

Blink1

Fuel Filter Warning

ON2


Fuel SystemFuel Warning System– Detection conditions

OFF for 10 min. or more

OFF is detected for 2 times 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 SystemAlternator Pulley

• In order to absorb a engine fluctuation, one-way clutch was adopted in the pulley

RollerSpring


Charging SystemAlternator Pulley– Engine fluctuation absorbing mechanism

EngineFluctuation

Alternator Pulley Speed

Crankshaft Pulley Speed

Pulle

y Sp

eed

(rpm

)

Time

One-wayClutch

Locked

One-wayClutchFree


Serpentine Belt Drive SystemSerpentine Belt Drive– Single V-ribbed belt

Alternator Pulley with Shock

Absorbing Function

Water Pump Pulley

Air Conditioner Compressor Pulley

Idler Pulley for Automatic Tensioner

Idler Pulley

Idler Pulley

Crankshaft Pulley


Engine Control SystemOil Maintenance Management System– This system determines the deterioration conditions of

the engine oil


Engine Control SystemOil Maintenance Management System– System diagram and general operation

Soot Volume ODO / TRIP

Switch

Engine ECUEngine Oil Change

Reminder Light

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

Meter ECU

Vehicle Speed

Blink or ON

Soot Volume Calculation


Engine Control SystemOil Maintenance Management System– Soot calculating logic

A/F Ratio

Injection End Timing

SootVolume

RichLean

Retard

Advance


Engine Control SystemOil Maintenance Management System– Engine oil change reminder light operation

Condition Engine Oil Change Reminder Light

Mileage = 35,000 km ~ 40,000 kmor

Specified Soot Volume A

Mileage = 40,000 km or more or

Specified Soot Volume B


ReferenceIntake Shutter Valve– Intake shutter valve position sensor

Intake Shutter Valve Opening Angle (°)

Outp

ut V

olta

ge (V

)0

Engine ECU

VC

VLU

Hall ICMagnet

E20

(Full Close)70

(Full Open)Intake Shutter Valve Position

Sensor

1

5

0.7120 100

3.51


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

• Non-contact type position sensor

0-55 550.5

2.5

4.5

Sensor shaft rotation angle ()

Outp

ut V

olta

ge (V

)

Output characteristic of main, sub sensor

VN CloseVN Open

-55 55

Hall ICs

MagnetsCross-section

0


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

From Supply Pump / Injector

To Fuel Tank

Fuel Cooler(Aluminum)

Front


ReferenceFuel Cooler– Construction

FromSupply Pump / InjectorTo Fuel Tank

Cross Section

Fin


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

usedAccelerator Pedal Position Sensor


ReferenceAccelerator Pedal– Using magnet and hall IC

Accelerator Pedal Depressed Angle

Full OpenFull Close

VPA1

VPA2

Outp

ut V

olta

ge (V

)0

5

VCP1

VCP2

VPA2

VPA1

Hall IC

Magnets

EP1

EP2

Engine ECU

Accelerator Pedal Position

Sensor

Mesin Diesel Toyota tipe 2 KD FTV 14

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Transcript of Mesin Diesel Toyota tipe 2 KD FTV 14