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
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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)
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ECD System Components

Supply Pump (HP3) Fuel flow

Click! Movie

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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

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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

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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

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ECD System Components

Turbo Pressure Sensor (PIM)

Turbo Pressure Sensor

Engine ECU
VSV (for Turbo Pressure Sensor)

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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

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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

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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

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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

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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

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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

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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

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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)

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