Tài liệu Commonrail

Model Outline KD Series Engine Contents  Click a Section Tab Chassis Body Body Electrical Model Outline KD Series Engine Chassis Engine Overall Engine Proper Valve Mechanism Lubrication System Intake and Exhaust System Common-rail System Fuel System Charging System Serpentine Belt Drive System Engine Control System Body Body Electrical 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 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 Mechanism 16-Valve DOHC, Belt & Gear Drive  Fuel System Common-Rail Type  With Without / With *2 2,982 (182.0) 2,492 (152.2) 96.0 x 103.0 (3.78 x 4.06) 92.0 x 93.8 (3.62 x 3.69) 18.4 18.5 120 @ 3,400 75 @ 3,600 88 @ 3,600 *2 343 @1,400 ~ 3,200 200 @ 1,400 ~ 3,200 260 @ 1,600 ~ 2,400 *1 320 @ 2,000 *2 Intercooler Displacement Bore x Stroke cm3 (cu in.) mm (in.) Compression Ratio Max Output Max Torque kW @ rpm N·m @ rpm *1: 2KD-FTV High Version *2: 2KD-FTV High Version (HILUX for Thai only) Model Outline KD Series Engine Chassis Body Body Electrical Engine Overall Features – Engine compartment Rotary Solenoid Type Diesel Throttle VN Type Turbocharger (1KD only) Photo: 1KD-FTV SLLC Fuel Filter •Fuel filter warning (clogging detection) •Element replacing type Model Outline KD Series Engine Chassis Body Body Electrical Engine Overall Features – Under floor Front Fuel Cooler (with intercooler model only) 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 Combustion Chamber SIRM Ring Carrier Ni-resist Cast Iron Ring Carrier Cooling Channel 1KD-FTV 2KD-FTV Model Outline KD Series Engine Chassis Body Body Electrical Valve Mechanism Timing Belt – Maintenance interval: replace at every 150,000 km Camshaft Timing Pulley No Oil Pump Drive Gear Crankshaft Timing Gear Supply Pump Drive Gear Timing Belt Automatic Belt Tensioner Camshaft Timing Pulley No Vacuum Pump Drive Gear Idle Gear Model Outline KD Series Engine Chassis Body Body Electrical Lubrication System Lubrication System – Overall • Lubrication is fully pressurized and all oil passes through an oil cooler and oil filter Oil Filter Oil Cooler 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 performance Engine Condition Valve Position Starting Full Open Reduced Diesel Smoke Running Small Full Open Controls EGR amount Stop Full Close Purpose Reduced noise and vibration Air flow Intake Shutter Valve Rotary Solenoid type Motor Intake Shutter Valve Position Sensor Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Warning System – Detection conditions After Afterthe thedriving drivingfor for30 30min min.or ormore more Fuel Filter Warning Switch Condition OFF OFF for for 10 10 min or more or more or OFF OFF is is detected detected for for 22 times during trip times during trip The warning light keeps ON until the reset operation is done Model Outline KD Series Engine Chassis Body Body Electrical Charging System Alternator Pulley • In order to absorb a engine fluctuation, one-way clutch was adopted in the pulley Spring Roller Model Outline KD Series Engine Chassis Body Body Electrical Charging System Alternator Pulley – Engine fluctuation absorbing mechanism One-way Clutch Locked Crankshaft Pulley Speed One-way Clutch Free Pulley Speed (rpm) Alternator Pulley Speed Engine Fluctuation Time Model Outline KD Series Engine Chassis Body Body Electrical Serpentine Belt Drive System Serpentine Belt Drive – Single V-ribbed belt Air Conditioner Compressor Pulley Idler Pulley Idler Pulley Water Pump Pulley Alternator Pulley with Shock Absorbing Function Idler Pulley for Automatic Tensioner Crankshaft Pulley Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System Oil Maintenance Management System – This system determines the deterioration conditions of the engine oil Model Outline Chassis KD Series Engine Body Body Electrical Engine Control System Oil Maintenance Management System – System diagram and general operation Engine Oil Change Reminder Light Engine ECU Blink or ON ••Engine Engine Speed Speed ••Injection Injection Volume Volume ••Injection Injection Timing Timing ••A/F Ratio A/F Ratio Meter ECU Soot Volume ODO / TRIP Switch Soot Soot Volume Volume Calculation Calculation Vehicle Speed Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System Oil Maintenance Management System – Soot calculating logic Soot Volume Retard Injection End Timing Rich A/F Ratio Lean Advance Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System  Oil Maintenance Management System – Engine oil change reminder light operation Condition Mileage = 35,000 km ~ 40,000 km or Specified Soot Volume A Mileage = 40,000 km or more or Specified Soot Volume B Engine Oil Change Reminder Light Model Outline KD Series Engine Chassis Body Body Electrical Model Outline KD Series Engine Chassis Body Body Electrical Reference Intake Shutter Valve – Intake shutter valve position sensor Magnet Hall IC Output Voltage (V) VC Engine ECU VLU E2 3.51 0.71 20 (Full Close) Intake Shutter Intake Shutter Valve Position Valve Position Sensor Sensor 70 (Full Open) Intake Shutter Valve Opening Angle (°) 100 Model Outline KD Series Engine Chassis Body Body Electrical Reference Variable Nozzle Vane Type Turbocharger (1KD only) – Nozzle Vane Position Sensor • Non-contact type position sensor Hall ICs Magnets Cross-section 0 -55  55  Output Voltage (V) Output characteristic of main, sub sensor 4.5 VN 2.5 0.5 -55 en p O e los C VN 55 Sensor shaft rotation angle () Model Outline KD Series Engine Chassis Body Body Electrical Reference Fuel Cooler – A fuel cooler cools the return fuel – It is used on the model equipped with an intercooler Front Fuel Cooler (Aluminum) From Supply Pump / Injector To Fuel Tank Model Outline KD Series Engine Chassis Body Body Electrical Reference Fuel Cooler – Construction Fin Cross Section To Fuel Tank From Supply Pump / Injector Model Outline KD Series Engine Chassis Body Body Electrical Reference Accelerator Pedal – Non-contact type accelerator pedal position sensor is used Accelerator Pedal Position Sensor Model Outline KD Series Engine Chassis Body Body Electrical Reference Accelerator Pedal – Using magnet and hall IC VCP1 Magnet s VPA1 Output Voltage (V)  EP1 VCP2 Hall IC VPA2 EP2 Accelerator Pedal Position Sensor VPA2 VPA1 Full Close Engine ECU Full Open Accelerator Pedal Depressed Angle