Transcription
TOYOTA 1KD/2KD ENGINECOMMON RAIL SYSTEM (CRS)Issued : September 200900400706E
2009 DENSO CORPORATIONAll rights reserved. This material may not be reproducedor copied, in whole or in part, without the writtenpermission of DENSO Corporation.
Table of ContentsTable of ContentsOperation Section1. PRODUCT APPLICATION INFORMATION1.1OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3Applicable Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.4System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52. SUPPLY PUMP2.1Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62.2Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63. RAIL3.1Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84. INJECTOR4.1Change Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94.2Quick Response (QR) Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105. FUEL INJECTION CONTROL5.1Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115.2Injection Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115.3Microinjection Quantity Learning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115.4Wide-Range Cylinder Correction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-136. DIAGNOSTIC TROUBLE CODES (DTC)6.1DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-157. ENGINE ECU7.1LAND CRUISER PRADO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-197.2DYNA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-227.3IMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Operation Section1 11. PRODUCT APPLICATION INFORMATION1.1 OUTLINEMinor changes have been made to the TOYOTA LAND CRUISER, PRADO, DYNA, and IMV. As a result, aportion of the Common Rail System (CRS) equipped with the 1KD-FTV and 2KD-FTV engines haschanged. The construction, operation, and control of main CRS components (supply pump, injectors, rail)are identical to the components described in the previously issued "Common Rail System for TOYOTAHILUX/KIJYANG INNOVA/INNOVA 1KD/2KD (Doc ID: 00400077)". Primary changes and additions arelisted below.The supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type.(refer to P1-6)The rail pressure limiter has been replaced with a pressure discharge valve. (refer to P1-8The injectors have been changed from the G2 type to the G3 type. (refer to P1-9)Microinjection quantity learning control, and wide-range cylinder correction control have been added toinjector control. (refer to P1-11)1.2 Applicable VehiclesVehicle NameLAND CRUISER PRADODYNAIMVEngine TypeEngine Displacement1KD-FTV3.0 L1KD/2KD-FTV3.0 L/2.5 LRemarksAugust 20091.3 Applicable Product ListLAND CRUISER PRADODENSOManufacturerPart NumberPart NumberSupply 0N10AT, 4WD, Europe, Australia, Euro 4275900-046#89661-60N30AT, 4WD, Middle East, General, Euro 3, 2275900-047#89661-60N50AT, 4WD, Middle East, General, Euro 0275900-048#89661-60N20MT, 4WD, Europe, Australia, Euro 4275900-049#89661-60N40MT, 4WD, Middle East, General, Euro 3, 2275900-050#89661-60N60MT, 4WD, Middle East, General, Euro 0131000-155#89871-25010Part NameEngine ECUEDURemarks
Operation SectionPart NameCrankshaft PositionSensorCamshaft PositionSensorAccelerator PedalModuleManifold AbsolutePressure (MAP) SensorCoolant TemperatureSensorIntake Air TemperatureSensorExhaustRecirculation1 2DENSOManufacturerPart NumberPart 5800-30190DENSOManufacturerPart NumberPart Number294000-070#22100-30090SCV: 294200-004#295050-007#23670-30380Different connector, for use with cylinders 1RemarksGas(EGR)ValveDYNAPart NameSupply Pumpand 33030071500-237#89727-60010Engine ECUEDUCrankshaft PositionSensorCamshaft PositionSensorAccelerator PedalModuleMAP SensorCoolant TemperatureSensorIntake Air TemperatureSensorRemarksMT, 2WD, Europe, Euro 4 (C/D), withcharging regulation when startingMT, 2WD, Europe, Euro 4 (C/D), withoutcharging regulation when starting
Operation Section1 3Part NameThrottle PositionSensorEGR ValveDENSOManufacturerPart NumberPart 101397-121#25800-30150DENSOManufacturerPart NumberPart Number294000-094#22100-301201KD, Europe, low lubrication294000-070#22100-300901KD/2KD, ThailandSM294000-090#22100-0L0601KD, Europe, Australia, ThailandSM294000-091#22100-0L0701KD/2KD, Europe, Thailand, India, lowRemarksIMVPart NameSupply PumpRemarkslubricationInjectorRailEngine ECUEngine 001KD, MT, PT-4WD, Europe, Euro 4MA275900-056#89661-0KN201KD, MT, 2WD, Australia, Euro 4MA275900-057#89661-0KN301KD, MT, PT-4WD, Australia, Euro 4MA275900-058#89661-0KN401KD, AT, PT-4WD, Europe, Euro 4MA275900-059#89661-0KN601KD, AT, PT-4WD PRE, Australia, Euro 4MA275900-060#89661-0KN802KD, MT, 2WD, Europe, Euro 4 Class 2MA275900-061#89661-0KP002KD, MT, 2WD, Europe, Euro 4 Class 3MA275900-062#89661-0KP202KD, MT, PT-4WD, Europe, Euro 4MA275900-063#89661-0KP402KD, MT, 2WD PRE, Thailand, Euro 3MA275900-064#89661-0KP502KD, MT, PT-4WD, Thailand, Euro 3RB275900-065#89661-0KN101KD, MT, PT-4WD, Europe, Euro 4RB275900-066#89661-0KN501KD, AT, PT-4WD, Europe, Euro 4RB275900-067#89661-0KN902KD, MT, 2WD, Europe, Euro 4 Class 2RB275900-068#89661-0KP102KD, MT, 2WD, Europe, Euro 4 Class 3RB275900-069#89661-0KP302KD, MT, PT-4WD, Europe, Euro 4HA275900-070#89661-0KN701KD, MT, FT-4WD, India, Euro 71070101310-591#89870-710802KD, MT, 2WD, India, Euro 4 (W/O OBD)
Operation SectionPart NameCrankshaft PositionSensorCamshaft PositionSensorMAP SensorCoolant TemperatureSensorIntake Air TemperatureSensorEGR ValveDENSOManufacturerPart NumberPart 5800-30110101397-116#25800-30120Remarks1 4
1 5Operation Section1.4 System OutlineThe CRS configuration is as per the figure below.
Operation Section1 62. SUPPLY PUMP2.1 Change ItemThe supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type. (Referto [SCV types (SV1, SV2)] on P1-7.)2.2 Suction Control Valve (SCV)The supply pump is equipped with a normally closed type SCV.When the solenoid is energized, the needle valve is pressed upon (in the compact SCV, the cylinder ispulled upon) by the armature, completely opening the fuel passage and supplying fuel to the plunger. (Totalquantity suctionedTotal quantity discharged)When power is removed from the solenoid, the return spring presses the needle valve back to the originalposition, closing the fuel passage.The solenoid is actuated by duty ratio control. Fuel is supplied in an amount corresponding to the opensurface area of the passage, which depends on the duty ratio. The fuel is then discharged by the plungers.
1 7Operation SectionOperational Concept DiagramOperation(1) SCV types (SV1, SV2)The SCV is available in the SV1 type and SV2 type. The SV2 is a compact SCV, while the SV1 is a bitlarger than the SV2.
Operation Section1 83. RAIL3.1 Change ItemBeginning from August 2006 model vehicles, a pressure discharge valve is used in place of the rail pressurelimiter. The engine ECU control and an actuation circuit (EDU) control the pressure discharge valve.
1 9Operation Section4. INJECTOR4.1 Change ItemsThe injectors used with the 1KD-FTV and 2KD-FTV engines have been changed from the G2 type to theG3 type. In comparison to the G2 type injector, the G3 type injector has the following characteristics:The nozzle shape, and shape of the high-pressure seal service have been changed, resulting in a morehigh-pressure resistant structure.The G3 injector is more highly responsive due to changes to the nozzle and solenoid valve.In consideration of the mounting measurements, the overall length for the 295050-008# injector (for usewith cylinders 1 and 2 in the DYNA) has been made shorter by 5.5 mm.
Operation Section1 104.2 Quick Response (QR) CodesQR codes are used to improve the accuracy of the injector injection quantity. The code from the vehicleassembly line is read, then entered into the engine ECU. Similar to the assembly line process, whenperforming service, the ID code is read by a diagnostic tool, and entered into the engine ECU.The injection quantity correction points contained in the injector QR code are shown in the figure below.
1 11Operation Section5. FUEL INJECTION CONTROL5.1 Change ItemMicroinjection quantity learning control, and wide-range cylinder correction control have been added to theCRS equipped with the 1KD-FTV and 2KD-FTV engines.5.2 Injection PatternIn this CRS system, injection occurs a maximum of three times. under normal operations, fuel injectioncontrol is performed with a pilot injection and a main injection. However, an additional pilot injection is addedwhen the engine is started at cold temperatures, as well as when the engine is operating in the lowtemperature, low-rotation speed range.5.3 Microinjection Quantity Learning Control(1) OutlineIn microinjection quantity learning control, the actual injector injection quantity is estimated from thechange in engine rotational speed that accompanies a very small injection. The difference between theestimated actual injection quantity, and the injection quantity command value at that time are learned bythe engine ECU. This difference is then used to correct the actual injection quantity.(2) GoalMicroinjection quantity learning control is used to accomplish the following: 1) to minimize injectionquantity deviations due to injector deterioration over time, and 2) to prevent both engine running noisedue to misfires and exhaust smoke.(3) Control outlineMicroinjection quantity learning control is automatically performed approximately every 2000 km ofnormal vehicle operation, and is completed after the vehicle has traveled approximately 500 km. Actuallearning takes place during the following processes.
Operation Section1 12Determination for learning conditionsMicroinjection quantity learning control is performed when the following two engine operations areestablished: 1) a reduction in vehicle speed, and 2) injection is cut off. In the determination process, theengine ECU then judges whether or not the conditions for learning have been met. The figure belowshows the specific details for learning determinations.Single microinjection operationUnder the single microinjection operation process, microinjection is performed once the following itemsare set: 1) the cylinder for which learning will be performed, and 2) the injection quantity. The figurebelow shows the specific settings and controls for a single microinjection.Detecting the change in rotational speed via injectionIn this process, the change in rotational speed can be detected using the set microinjection. The figurebelow shows the processing for calculating changes in rotational speed.
1 13Operation SectionCorrecting the injection pulse width (TQ), and actual injection quantity (Q) characteristicsIn this process, the actual injection quantity is estimated from the set microinjection, and the change inrotational speed. The actual injection quantity is then corrected such that the value equals the targetinjection quantity. The figure below shows the processing for the aforementioned corrections.[ REFERENCE ]Learning must be performed manually when either an injector (or injectors), or the engine ECU is replaced.As per the figure below, diagnostic tools are used to perform learning while the engine is operating.5.4 Wide-Range Cylinder Correction Control(1) OutlineIn wide-range cylinder correction control, the combustion sta
Minor changes have been made to the TOYOTA LAND CRUISER, PRADO, DYNA, and IMV. As a result, a portion of the Common Rail System (CRS) equipped with the 1KD-FTV and 2KD-FTV engines has changed. The construction, operation, and control of main CRS components (supply pump, injectors, rail) are identical to the components described in the previously issued "Common Rail System for
