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Mesin Secara Umum
Z 22 xx xxxxxx K
1 2 3 4 5
Z 22 xx xxxxxx K
1 2 3 4 5
Spesifikasi Mesin
2.2L DOHC-Diesel
4 Cylinder(In-Line)
16.3 : 1
725
Roller Finger Follower
Hydraulic Lash Adjustment
Chain...
Engine specifications
2.2L DOHC-Diesel
Electric motor in fuel tank
Depth Media
165 ~215(at 4.5 bar)
4.15 ~5.35
Common rail...
Engine overview
Cylinder head
Front side
(Timing Chain side)
Rear Side
(Transmisson side)
Exhaust side
Intake side
DOHC
4 valves per cyl...
Cylinder block
made of grey iron with sand casting process
ties up with lower crankcase (Bedplate)
Piston & Road assembly
cast aluminum
a bowl type combustion chamber
Skirt of piston is coated with polymer
full-floati...
Crankshaft
made of high strength forged steel
5 main bearings
 thrust bearing placed in the 3rd
crank bore
At the 6th ...
Oil Pump & Balance shaft module
Valve train system
a
b
c
ed
f
g
h
i
j
k
l
DOHC
hydraulic lash adjuster
Intake cam shaft has a
chain sprocket with
integ...
Engine oil distribution
Engine oil distribution
ITEMS 2.2L Diesel
Oil Type and Grade Dexos2 5W30
Oil Filter Cartridge
Oil Capacity (w/filter) 5.6 ...
Engine oil seal (crankshaft rear oil
seal)
ISO View
(PTFE Reverse laydown lip
type)
Assembly View
Cyl. Block
Crankshaft
[S...
Engine Oil Cooler
Oil pan (two piece)
Engine oil pressure switch
Engine oil level switch
Timing chain component
b
a
c
ed
f
g
h
Timing chain adjustment (Removal)
Timing chain adjustment (Removal)
Timing chain adjustment(Installation)
1.Install the crankshaft sprocket
(1) with the timing chain mark at the 4
o’clock po...
Timing chain adjustment (Installation)
Timing chain adjustment (Installation)
EN-955-1
Crankshaft pulley with drive belt
[Crank pulley] [Section View]
Damper rubber
Isolation rubber
Vacuum pump
VGT, Swirl, EGR
Brake
PCV valve
2
1
3
: Blow by gas
: Fresh air + Blow by
4
1. PCV hose
2. PCV valve assembly(W/OIL SEP)
3. Turbo charger
4. Int...
PCV valve
PCV valvePCV valve
Coolant circuit diagram
General
description of
Turbocharger
Piston
Inter-cooler
Intake valve
Exhaust valveTurbo charger
Intake air
Turbine
Compres...
Description of Variable Geometry
Turbocharger (VGT)
Boost pressure actuator
Engine
status
Actuator Operation status Remarks
Low speed
(Low load)
Pull
** Increase MAX.
torque....
Intake manifold pressure &
Temperature sensor (TMAP sensor)
TMAP sensor
Description of Diesel common rail
system
High pressure pump
Fuel inlet
Fuel outlet to rail
Fuel return to fuel tank
Fuel return from injectors
Inlet metering valve...
High pressure pump basic functioning
02.3-11
Showing 3 radial plungers, 2 plungers similar
High pressure pump
Part Item Specification Remarks
High pressure
pump
Type 2 cylinder plunger
Pump output
capacity
970 mm3...
High pressure pump
Common rail
Fuel outlet to injector
Rail pressure sensor
Fuel inlet
from pump
Common rail
Part Item Specification Remarks
Common rail Rail pressure Max. 1800bar
Rail pressure sensor
Type Piezo Resisto...
Injector
Fuel Return
Fuel Inlet
IQA code
Nozzle
IQA code
Injector
Part Item Specification Remarks
Injector
Type Solenoid Multi injection type
Injection hole 8 holes
Operating temp...
Diesel common rail basic
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Diesel common rail basic

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Diesel common rail basic

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Diesel common rail basic

  1. 1. Mesin Secara Umum Z 22 xx xxxxxx K 1 2 3 4 5 Z 22 xx xxxxxx K 1 2 3 4 5
  2. 2. Spesifikasi Mesin 2.2L DOHC-Diesel 4 Cylinder(In-Line) 16.3 : 1 725 Roller Finger Follower Hydraulic Lash Adjustment Chain Drive Compression ignition system 1-3-4-2 Ignition Bore x Stroke (mm) Displacement (cc) Turbo Charger Valve Lash Adjustment Type Ignition sequence Max Combustion Peak Pressure Idle RPM APPLICATION Engine General Engine type Timing Drive Max Power (hp/RPM) Max Torque (Nm/RPM) Compression Ratio Cam Follower
  3. 3. Engine specifications 2.2L DOHC-Diesel Electric motor in fuel tank Depth Media 165 ~215(at 4.5 bar) 4.15 ~5.35 Common rail 3 cylinder radial plunger 695 ㎣ / rev Max 1400 bar Max 1400 bar Cartridge 50 L Low pressure pump Pump type High pressure pump Pump type Fuel pressure (bar) Injector pressure (bar) APPLICATION Filter type Displacement (㎣) Fuel Delivery Filter type Displacement (ℓ /H) Fuel pressure (bar) Filter Type Fuel Tank Capacity
  4. 4. Engine overview
  5. 5. Cylinder head Front side (Timing Chain side) Rear Side (Transmisson side) Exhaust side Intake side DOHC 4 valves per cylinder  roller type : finger followers Drive vacuum pump Drive high pressure fuel pump made of aluminum
  6. 6. Cylinder block made of grey iron with sand casting process ties up with lower crankcase (Bedplate)
  7. 7. Piston & Road assembly cast aluminum a bowl type combustion chamber Skirt of piston is coated with polymer full-floating type piston Fractured connecting rod
  8. 8. Crankshaft made of high strength forged steel 5 main bearings  thrust bearing placed in the 3rd crank bore At the 6th of crankshaft arm, a crankshaft gear is hot press fitted to drive a balance shaft target wheel is assembled at the 8th of crankshaft arm,
  9. 9. Oil Pump & Balance shaft module
  10. 10. Valve train system a b c ed f g h i j k l DOHC hydraulic lash adjuster Intake cam shaft has a chain sprocket with integrated spur gear is driven by chain exhaust cam shaft driven by scissors gear Intake cam drives High pressure fuel pump Exhaust cam drives mechanical vacuum pump
  11. 11. Engine oil distribution
  12. 12. Engine oil distribution ITEMS 2.2L Diesel Oil Type and Grade Dexos2 5W30 Oil Filter Cartridge Oil Capacity (w/filter) 5.6 L Oil Change interval 1 year or oil change lamp-on
  13. 13. Engine oil seal (crankshaft rear oil seal) ISO View (PTFE Reverse laydown lip type) Assembly View Cyl. Block Crankshaft [Section view (After
  14. 14. Engine Oil Cooler
  15. 15. Oil pan (two piece)
  16. 16. Engine oil pressure switch
  17. 17. Engine oil level switch
  18. 18. Timing chain component b a c ed f g h
  19. 19. Timing chain adjustment (Removal)
  20. 20. Timing chain adjustment (Removal)
  21. 21. Timing chain adjustment(Installation) 1.Install the crankshaft sprocket (1) with the timing chain mark at the 4 o’clock position. Note: Ensure the crankshaft key (2) is aligned with the crankshaft timing mark (3). Note: Ensure the camshaft dowel (4) is at the 12 o’clock position and the camshaft sprocket timing marks are at the 12 an 3 o’clock positions as shown.
  22. 22. Timing chain adjustment (Installation)
  23. 23. Timing chain adjustment (Installation) EN-955-1
  24. 24. Crankshaft pulley with drive belt [Crank pulley] [Section View] Damper rubber Isolation rubber
  25. 25. Vacuum pump VGT, Swirl, EGR Brake
  26. 26. PCV valve 2 1 3 : Blow by gas : Fresh air + Blow by 4 1. PCV hose 2. PCV valve assembly(W/OIL SEP) 3. Turbo charger 4. Intake manifold
  27. 27. PCV valve PCV valvePCV valve
  28. 28. Coolant circuit diagram
  29. 29. General description of Turbocharger Piston Inter-cooler Intake valve Exhaust valveTurbo charger Intake air Turbine Compressor Inter-cooler Throttle body Exhaust gas Intake air
  30. 30. Description of Variable Geometry Turbocharger (VGT)
  31. 31. Boost pressure actuator Engine status Actuator Operation status Remarks Low speed (Low load) Pull ** Increase MAX. torque. High speed (High load) Release **Increase MAX. power.
  32. 32. Intake manifold pressure & Temperature sensor (TMAP sensor) TMAP sensor
  33. 33. Description of Diesel common rail system
  34. 34. High pressure pump Fuel inlet Fuel outlet to rail Fuel return to fuel tank Fuel return from injectors Inlet metering valve Oldham Coupling Cylinder Cylinder
  35. 35. High pressure pump basic functioning 02.3-11 Showing 3 radial plungers, 2 plungers similar
  36. 36. High pressure pump Part Item Specification Remarks High pressure pump Type 2 cylinder plunger Pump output capacity 970 mm3 /rev Output pressure 230 bar Idle 1800 bar Max. Power Inlet Metering Valve Type Solenoid PWM control Resistance 4.77 5.83 Ω∼ Operating frequency 300 2000 Hz∼
  37. 37. High pressure pump
  38. 38. Common rail Fuel outlet to injector Rail pressure sensor Fuel inlet from pump
  39. 39. Common rail Part Item Specification Remarks Common rail Rail pressure Max. 1800bar Rail pressure sensor Type Piezo Resistor Supply Voltage 5V Output Voltage 0.5 - 4.5 V 5V Ref 3 Signal 2 1 Rail Pressure Sensor J1 35 J1 38 J1 19 ECM
  40. 40. Injector Fuel Return Fuel Inlet IQA code Nozzle IQA code
  41. 41. Injector Part Item Specification Remarks Injector Type Solenoid Multi injection type Injection hole 8 holes Operating temperature -30 120∼ ℃ Max. Injection pressure 1400 bar Min. Injection pressure 150 bar Normal Injection pressure 230 1400bar∼ Return pressure Pabs < 900 mb

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