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MANUAL ENGINE 1/2KD-FTV TOYOTA SISTEMA COMNON RAIL

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MANUAL ENGINE 1/2KD-FTV TOYOTA SISTEMA COMNON RAIL

  1. 1. ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-137 Supply Pump 1) General This supply pump (HP3 type) has been made shorter than the HP2 type that is used on other models. This has been accomplished through the adoption of an opposing plunger configuration (and by reducing the number of plungers from 4 to 2), resulting in a compact and lightweight supply pump. 4Specifications3 Model New Hilux Other Model Type HP3 (Outer Cam) HP2 (Inner Cam) A Length mm (in.) 190.2 (7.49) 252.0 (9.92) B Length mm (in.) 129.0 (5.08) 182.1 (7.17) Suction Control Valve 1 2 Plunger φ8.5×2 φ7.0×4 Weight g (lb.) 3,800 (8.38) 6,040 (13.32) 224EG21 HP2 A B The engine ECU learns and memorizes the pump discharge volume variances associated with the individual differences in the supply pumps. Therefore, make sure to perform the operation described below after replacing the supply pump. For details, see the Hilux Repair Manual. • Connect an intelligent tester II to the DLC3 connector and use the tester to reset the learned value. Alternatively, connect the SST (09843-18040) between the TC and CG terminals of the DLC3 connector, and leave the ignition switch ON for approximately 3 minutes to reset the learned value. • After resetting, start the engine, allow it to idle* for approximately 1 minute, and turn the ignition switch OFF to enable the engine to memorize the learned value. *: The engine coolant temperature should be 60°C (140°F) or more, and the fuel temperature should be 20°C (68°F) or more. Service Tip 271EG155 HP3 A B
  2. 2. ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-138 2) Construction • The supply pump consists of an eccentric camshaft, ring cam, two plungers, four check valves, SCV (Suction Control Valve), fuel temperature sensor, and a feed pump. • The two plungers are placed opposite each other outside of the ring cam. Plunger Plunger Ring Cam Feed Pump Eccentric Camshaft 271EG157 271EG158 Eccentric Cam Portion Eccentric Cam Portion Ring Cam Check Valve (for Suction) Check Valve (for Discharge) Check Valve (for Suction) SCV Feed Pump to Common-rail Fuel Temp. Sensor Eccentric Camshaft Ring Cam 271EG156 Plunger Check Valve (for Suction) Plunger Check Valve (for Suction) from Fuel Tank (for Suction) to Fuel Tank (for Return) Check Valve (for Discharge)
  3. 3. ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-139 3) Operation • Due to the rotation of the eccentric cam, the ring cam pushes plunger “A” upward as illustrated below. The force of the spring pulls plunger “B” (which is located opposite plunger “A”) upward. As a result, plunger B draws fuel in, and plunger “A” pumps fuel at the same time. • The SCV controls the volume of fuel that is drawn into the plungers in accordance with the signals from the engine ECU. Engine ECU Engine ECU Engine ECU Engine ECU B Ring Cam Eccentric Cam Check Valve (for Discharge) Check Valve (for Suction) A SCV 245EG08
  4. 4. ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-140 Common-Rail • The function of the common-rail is to store the fuel that has been pressurized by the supply pump. The common-rail is provided with a fuel pressure sensor, which detects the fuel pressure in the common-rail, and a pressure limiter that mechanically relieves the pressure in case the internal pressure of the common-rail rises abnormally. • Internally, the common-rail contains a main hole and five branch holes that intersect the main hole. Each branch hole functions as an orifice that dampens the fluctuation of the fuel pressure. • Fuel pressure sensor has its sealing portion plastic-deformed in order to keep sealing performance, so do not reuse it after disassembling. • If parts that affect the alignment have been changed, make sure to replace the pipe with a new one as well. The parts that require the replacement of a pipe are listed below. Injection Pipe: Injector, Common-rail, and Cylinder Head Fuel Inlet Pipe: Supply Pump, Common-rail, Cylinder Block, Water Pump, and Cylinder Head For details, refer to the Hilux Repair Manual. Service Tip Fuel Pressure Sensor to Injectors from Supply Pump Pressure Limiter Branch Hole Main Hole Common-Rail Cross Section 271EG125
  5. 5. ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-141 Injector 1) General • An injector consists of a nozzle needle, piston, and solenoid valve. • An injector compensation value and QR (Quick Response) code containing encoded characteristics of the injector are printed on each injector. • The injector compensation value and QR code contain various pieces of information regarding the injector, such as model code, and injection volume correction. • If the engine ECU is replace, use the intelligent tester II and input the injector compensation values of all 4 injectors. If the injector is replaced, input the injector compensation value of the replaced injector. Then, the proper compensation will be made so that the injection volume precision prior to the replacement will remain unchanged. For details, see the Hilux Repair Manual. • The QR code, which requires a special scan tool, is not used at Toyota dealers. Service Tip - REFERENCE - What is QR (Quick Response) Code? • QR code, a matrix symbology consisting of an array of nominally square cells, allows omni-directional, high-speed reading of large amounts of data. • QR code encodes many types of date such as numeric, alphanumeric, kanji, kana and binary code. A maximum of 7,089 characters (numeric) can be encoded. • QR code (2D code) contains information in the vertical and horizontal direction, whereas a bar code contains date in one direction only. QR code (2D code) holds a considerably greater volume of information than a bar code. 271EG152 Nozzle Needle Piston Solenoid Valve QR Code Injector Compensation Value 271EG153
  6. 6. ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-142 2) Operation (a) When electrical current is applied to the solenoid coil, it pulls the solenoid valve up. (b) The orifice of the control chamber opens, allowing the fuel to flow out. (c) The fuel pressure in the control chamber drops. (d) Simultaneously, fuel flows from the orifice to the bottom of the piston and raises the piston up (to enhance response). (e) As a result, the piston raises the nozzle needle to inject fuel. 271EG127 Fuel Solenoid Coil (a) Solenoid Valve Piston Control Chamber Nozzle Needle Fuel (b) (c) (d) (e)
  7. 7. ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-143 3. Fuel Filter General • The conventional fuel filter consists of a fuel filter element integrated with the fuel filter housing. By contrast, the new fuel filter consists of a separate fuel filter housing and a fuel filter element. • A paper filter element that offers high filtering efficiency and captures the minutest particles has been adopted. Fuel Filter Warning Switch • A fuel filter warning switch, which turns ON/OFF when the internal vacuum of the filter increases, is provided in the fuel filter. This switch, which turns OFF when the internal vacuum of the fuel filter increases to a predetermined level, is connected by wire to the meter ECU. • When the meter ECU detects that the internal vacuum of the fuel filter has increased (by way of the fuel filter warning switch OFF signal), it determines that the fuel filter has become clogged. Then, it illuminates the fuel filter warning light on the combination meter to urge the driver to replace the fuel filter. For details on fuel filter warning light control, see page BE-XX. 271EG129 Fuel Filter Warning Light Meter ECU Combination Meter Fuel Filter Warning Switch Diaphragm from Fuel Tank to Supply Pump Filter Element Fuel Filter Meter ECU Combination Meter Normal Fuel Filter Fuel Filter Clogged Up Negative Pressure (Vacuum) Fuel Filter Fuel Filter Warning Switch Filter Element Filter Housing Fuel Sedimenter Level Warning Switch New Conventional Fuel Sedimenter Level Warning Switch Fuel Filter Assembly • Filter Element Priming Pump Priming Pump 271EG128
  8. 8. ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-144 4. Fuel Cooler The fuel cooler, which is provided in the fuel return path, cools the return fuel that has reached a high temperature as a result of the pumping of the supply pump. This prevents the reduction in fuel viscosity that is caused by the rise in fuel temperature, and improves the reliability of the fuel system. A A A-A Cross Section to Fuel Tank from Common-Rail 271EG130

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