Referensi : Bahan Training TOYOTA
Common-rail Diesel Diagnosis Training
High-tech Diagnosis Course for Common-rail
Goals Reduce unnecessary replacing of parts (NTF parts reaches 70% in some cases) Reduce troubleshooting time
Improve overall customer satisfaction
High-tech Diagnosis Course for Common-rail
Objectives Improve system knowledge Learn DTC detection conditions Implement structured and logic troubleshooting procedures
History of Common-rail System
Different variations on Common-rail 3 Generations
Diesel EFI
Common-rail
1st-generation
Common-rail HP2 Supply Pump Solenoid Injector 2nd-generation HP3 Supply Pump Discharge Valve Injector Compensation Code 3rd-generation
135 MPa
Max. Commonrail Pressure
135 - 160 MPa
NSR + DPNR Piezo Injector
160 - 180 MPa
System Overview
Common-rail System Diagram (for IMV)
NE Signal G Signal Engine ECU
Other Injectors Pressure Limiter Common-rail
EDU
Various Signals
Fuel Pressure Sensor
Injector Pressure Switch
Fuel Cooler Fuel SCV Fuel SystemFilter Supply Pump Warning Light
Fuel Tank
System Overview
Main Components for Common-rail System Shown for the 1KD-FTV engine on the IMV
Engine Front
Injection Pipe
Injector
Fuel Inlet Pipe
SCV (Suction Control Valve) Fuel Temp. Sensor
Supply Pump
Fuel Pressure Sensor Pressure Limiter
Common-rail
System Overview
Features of Common-rail System
Injection pressure, volume and timing are controlled electrically High pressure fuel
High accuracy engine control
Higher atomization of fuel High pressure injection in all engine speed range
Stores high pressure fuel
High performance and fuel economy
Low noise and vibration Clean emission
8
System Overview
Sensors and Actuators
Air Flow Meter Atmospheric Temp. Sensor E-VRV (for EGR Valve Control) VSV (for EGR Valve Close) Camshaft Position Sensor
Intake Restrictor Valve (Step Motor) Intake Air Temp. Sensor Turbo Pressure Sensor VSV (for Turbo Pressure Sensor) Glow Plug Water Temp. Sensor
Injector
Crankshaft Position Sensor
Illustration is for 1CD-FTV on CDE120 9
ECD System Components
Supply Pump Supplies the high pressure fuel to the common-rail
HP2 HP3
Type
Generation SCV Plunger Weight [g (lb.)]
HP2 (Outer Cam)
1st 2 (Time controlled) 4 (Radial Type) 6040 (13.32)
HP3 (Inner cam)
2nd/3rd 1 (Duty-cycle) 2 (Opposite type) 3800 (8.38)
10
ECD System Components
Supply Pump (HP3) Fuel flow
Click! Movie
11
ECD System Components
Supply Pump (HP3) The SCV opening regulates the pumping volume to control fuel pressure
[Fuel Pressure Control]
Fuel Pressure Sensor
SCV Controls SCV opening
Common-rail pressure (Feedback)
Calculation of target injection pressure
Crankshaft Position Sensor
Engine ECU
Accelerator Pedal Position Sensor
12
ECD System Components
Injector High pressure injection for higher atomization
Solenoid Coil From Common-rail Control Chamber Nozzle Spring
Click! Movie
Solenoid Coil
Return to Fuel Tank
Nozzle Needle
Piston
Injector Hole
6 or 8
Nozzle Spring Nozzle Needle
13
Injector Pressure
Voltage
135 180 MPa
150 V
ECD System Components
Overview ECU Inputs
Basic Parameters Crankshaft Position Sensor (Ne) Accelerator Pedal Position Sensor (VA) Correction Parameters Intake Air Temp. Sensor (THA) Water Temp. Sensor (THW) Fuel Temp. Sensor (THF) Turbo Pressure Sensor (PIM) Vehicle Speed Sensor (SPD) Fuel Pressure Sensor (PCR) Ignition Switch (STA) Blower Switch (BLW) A/C Amplifier (AC) Alternator (ALT) DLC3 Injector
EDU
EGR Valve
Engine ECU
14
ECD System Components
Overview ECU Outputs
Injector (Timing and duration) Suction Control Valve Various Sensor EDU (Power supply)
Engine ECU
Intake Restrictor Valve Glow Plug EGR Valve DLC3
15
ECD System Components
Turbo Pressure Sensor (PIM)
Turbo Pressure Sensor
Engine ECU
VSV (for Turbo Pressure Sensor)
16
Common-rail Control Systems
Overall Consists mainly two parts, fuel metering part and fuel supply part
[Electrical Part]
Injection Volume Control Injection Timing Control Idle Speed Control Fuel Pressure Control Injection rate Control Turbo Control EGR Control Glow Control Diagnosis EDU
Various Sensor
Engine ECU
Supply Pump Common-rail
[Mechanical Part]
Injector
17
Common-rail Control Systems
Fuel Injection Volume Control Injection volume decision Engine ECU compares the basic and maximum injection volumes, and determine the smaller calculated value to be the final injection volume
Basic Injection Volume
Fuel Pressure
Compensation Value
EDU
Comparison
Decision on Duration
Maximum Injection Volume
Injector Feedback Value
Engine ECU
Injector
18
Common-rail Control Systems
Fuel Injection Volume Control Basic injection volume
Accelerator Pedal Position Sensor (VPA)
Crankshaft Position Sensor (Ne)
Basic Injection Volume (Map Data in ECU)
Water Temp. Sensor (THW)
+
Basic Injection Volume Correction Clutch Switch (CLSW) Vehicle Speed Sensor (SPD)
Engine ECU
ISC* Correction
*: Idle Speed Control
19
Common-rail Control Systems
Fuel Injection Volume Control Maximum injection volume
Crankshaft Position Sensor (Ne)
Overheating Protection
Water Temp. Sensor (THW) Fuel Temp. Sensor (THF)
Basic/Maximum Injection Volume (Map Data in ECU)
Maximum Injection Volume Correction
Fuel Pressure Sensor (PC, VPC) Intake Air Temp. Sensor (THA) Turbo Pressure Sensor (PIM) Air Flow Meter (VG)
Engine ECU
Intake Air Mass
20
Common-rail Control Systems
Fuel Injection Volume Control Injection duration
Decides opening time of injector by final injection volume Controls opening timing of injector
NE Signal G Signal Various Signals
Engine ECU
EDU
Common-rail From Supply Pump Fuel Pressure Sensor
Pressure Limiter
Injector
21
Common-rail Control Systems
Fuel Injection Volume Control Injection duration
Basic Injection Volume
Fuel Pressure
Comparison Volume
INJ Time Calculation
EDU
Maximum Injection Volume
Injector Compensation Value
Injector Feedback Value
Engine ECU
Injector
22
Common-rail Control Systems
Fuel Injection Volume Control Injection volume control during starting
Increase Correction Coefficient 1
Starting Injection Volume
Basic Injection Volume
40 Water Temperature (deg)
Ignition Switch (STA) Water Temp. Sensor Crankshaft Position Sensor
+
Corrections
Engine ECU
23
Common-rail Control Systems
Fuel Injection Timing Control Basic injection timing (injection timing control after started)
Accelerator Pedal Position Sensor (VPA) Crankshaft Position Sensor (Ne)
Basic Injection Timing
+
Injection Timing Correction
Intake Air Temp. Sensor (THA) Turbo Pressure Sensor (PIM) Water Temp. Sensor (THW) EDU Injector
Engine ECU
24
Common-rail Control Systems
Fuel Injection Timing Control Injection timing control during starting
Crankshaft Position Sensor (Ne) Target Injection Timing Correction Ignition Switch (STA) Water Temp. Sensor (THW)
Engine ECU
25
Common-rail Control Systems
Idle Speed Control Target idle speed control
Accelerator Pedal Position Sensor (VPA) Water Temp. Sensor (THW) Target Engine Speed Calculation Vehicle Speed Sensor (SPD) Ignition Switch (STA) A/C Amp. [Idle-up Signal] (ACT) Comparison Injector Volume Correction
Electric Load
Actual Engine Speed
Crankshaft Position Sensor (Ne)
Engine ECU
26
Common-rail Control Systems
Fuel Pressure Control Target injection fuel pressure
[Fuel Pressure Control]
Fuel Pressure Sensor
SCV Controls SCV opening
Common-rail pressure (Feedback) Calculation of target injection pressure Crankshaft Position Sensor
Engine ECU
Accelerator Pedal Position Sensor
27
Common-rail Control Systems
Injection Rate Control Pilot injection
Accelerator Pedal Position Sensor (VPA)
Crankshaft Position Sensor (Ne)
Basic Pilot Timing
Intake Air Temp. Sensor (THA) Turbo Pressure Sensor (PIM) Correction Water Temp. Sensor (THW)
Pilot Injection (Volume, Timing, Interval)
EDU Injector
Engine ECU
28
Common-rail Control Systems
Other System Operation EGR control system
Intake Restrictor Valve Position Sensor
Intake Restrictor Valve
Intake Restrictor Valve Control Motor
Engine ECU
Vacuum Pump
EGR Valve Position Sensor
Atmospheric Pressure Sensor
Crankshaft Position Sensor Accelerator Pedal Position Sensor Water Temp. Sensor Turbo Pressure Sensor Intake Air Temp. Sensor
Vacuum Damper EGR Valve E-VRV (for EGR valve control)
Engine
29
Common-rail Control Systems
Other System Operation Intake restrictor valve control system
Intake Restrictor Valve Control Motor
Crankshaft Position Sensor (Ne) Water Temp. Sensor (THW) Intake Air Temp. Sensor (THA) Accelerator Pedal Position Sensor (VPA)
Engine ECU
Intake Restrictor Valve Position Sensor
Intake Restrictor Valve
Turbo Pressure Sensor (PIM) Ignition Switch (STA)
30
