Kijang Inova Bensin VVT I 160825125752

Model Outline Mesin 1TR-FE Chassis Body Body Electrical
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Mesin Keseluruhan
Kelengkapan Mesin
Mekanisme Katup
Sistem Pendinginan
Sistem Intake dan Exhaust
Sistem Bahan Bakar
Sistem Pengapian
Sistem Serpentine Belt Drive
Engine Control System
Mesin Keseluruhan
Garis Besar
– Mesin 1TR-FE leaded gasoline, merupakan rancangan
baru in-line 4-cyliner, 2.0-liter, 16-valve DOHC
dengan VVT-i, chain drive
Mesin Keseluruhan
Spesifikasi Mesin
Model 1TR-FE 1RZ-E (KIJANG)
Jumlah silinder & susunan 4-cylinder, In-line ←
16-valve, DOHC with VVT-i, 8-valve, SOHC, Chain
Mekanisme Katup
Chain Drive Drive
Displacement [cm3 (cu. in.)] 1998 (121.9) ←
Bore x Stroke [mm (in.)] 86.0 x 86.0 (3.39 x 3.39) ←
Compression Ratio 9.8 : 1 9.0 : 1
Maximum Output
100 / 5,600 71 / 4,800
SAE-NET [kW / rpm]
Maximum Torque
182 / 4,000 152 / 2,800
SAE-NET [N·m / rpm]
Buka 0° ∼ 45° BTDC 13° BTDC
Intake
Tutup 64° ∼ 19° ABDC 47° ABDC
Valve Timing
Buka 44° BBDC 53° BBDC
Exhaust
Tutup 8° ATDC 7° ATDC
Fuel Octane Rating 91 atau lebih ←
5W-30 / API SL, SJ, EC or
Oil Viscosity / Oil Grade ←
ILSAC
Mesin Keseluruhan
Keseluruhan DIS and Long Reach
Type Spark Plug
Resin Type Long Nozzle

Cylinder Head Cover 4-hole Type Injector
Stainless Steel
Exhaust Manifold
Flat type
knock sensor
Segment
Conductor Type
Alternator
No-contact
Type Throttle
Position Sensor
VVT-i System
Resin Type
Intake Manifold
TOYOTA Genuine
Super LLC
Mesin Keseluruhan
Informasi Identifikasi
– Nomor mesin di cetak pada sisi kiri bawah blok mesin
Kelengkapan Mesin
Tutup Kepala Silinder
– Mengurangi konsumsi oli mesin yang melalui blow-by
gas, berat dan juga suaranya Ke Intake Manifold
Resin
Fresh
Air
Acrylic
Rubber Baffle
Plate
Kelengkapan Mesin
Kepala Silinder
– Terbuat dari aluminum alloy ringan
22.85°
Hydraulic Lash
Adjuster
Aluminum
Alloy
3-layer Steel
Taper Squish
Laminate
Kelengkapan Mesin
Blok Silinder
– Terbuat dari cast iron, memiliki sirip untuk
memperkuat rigiditas dan mengurangi suara dan
getaran
Cast Iron
Aluminum Alloy
Steel
Kelengkapan Mesin
Piston
– Dari bahan aluminum alloy, menggunakan ring piston
low tension untuk mengurangi keausan
Taper Squish Alumite Treatment for
Shape Top Ring Groove
[Low Tension Piston Rings]

PVD Coated 1st
Resin Coating Compression Ring
Chrome-plated 2nd
Compression Ring
2 Pieces Oil Ring
PVD: Physical Vapor Deposition

Kelengkapan Mesin
Bearing Crankshaft
– Bearing crankshaft yang tak memiliki kuku (claw)
– Permukaan bearing micro-grooved (alur halus)
[Bearing Atas] [Bearing Bawah]
Micro-grooved
Service Point (Kelengkapan Mesin)
Pemasangan Bearing Crankshaft Bagian Atas
– Posisi bearing harus berada di tengah journal blok
silinder untuk meluruskan lubangnya
[Upper Bearing]
[OK]
Center
Lubrication Hole
[NG]
Lubrication Hole
Pemasangan Bearing Crankshaft Bagian Bawah
– Bearing harus berada di tengah, ukur posisinya
[Perbedaan antara “B” dan “C”: 0.3 mm (0.012 in.) atau kurang]
B
Vernier
Caliper
Pemasangan Bearing Crankshaft
– Nilai Referensi
A
B
A
C
Vernier Caliper
Bearing Atas Bearing Bawah

Journal
Ukuran “A” [mm (in.)] Ukuran “B” atau “C” [mm (in.)]
#1, 5 3.75 (0.1476 ) ± 0.1 (0.004) 3.83 (0.1508) ± 0.1 (0.004)
#3 1.75 (0.0689 in.) ± 0.1 (0.004) 1.74 (0.0689) ± 0.1 (0.004)
#2, 4 2.75 (0.0183) ± 0.1 (0.004) 2.75 (0.0183) ± 0.1 (0.004)
Baut Puli Crankshaft
– Baut puli crankshaft tak boleh digunakan kembali
Crankshaft
Pulley Set Bolt
Mekanisme Katup
Keseluruhan
– Mekanisme Katup Terdiri dari roller rocker arm,
hydraulic lash adjuster dan sistem VVT-i
Oil Delivery Pipe Roller
(cam dan rocker arm) Rocker Arm
Exhaust
Valve
Hydraulic
Intake Valve Lash
Adjuster
Timing Chain
VVT-i Controller
Mekanisme Katup
Rocker Arm
– Roller rocker arm dengan built-in needle bearing
digunakan untuk mengurangi gesekan, sehingga
memperbaiki konsumsi bahan bakar
Oil Delivery Pipe

[Roller Rocker Arm]
Needle
Bearing
Roller Rocker Arm

Mekanisme Katup
Hydraulic Lash Adjuster
– Mempertahankan celah katup nol dengan
menggunakan tekanan oli dan tegangan pegas
Plunger
Low Pressure
Chamber
Zero Valve
Clearance Oil Passage
Check Ball
Check Ball Spring
High Pressure
Chamber
Plunger Spring
Oil Passage
Reference (Mekanisme Katup)
Roller Rocker Arm dan Hydraulic Lash Adjuster
Oil Passage
Oil Passage
Mekanisme Katup
– Cara Kerja
Service Point (Mekanisme Katup)
– Prosedur penggantian oli
1. Tekan check ball ke bawah dengan SST
SST
[SST: 09276-75010]
Hydraulic Lash
Benar Salah
Adjuster
2. Masukkan hydraulic lash adjuster pada oli mesin
bersih, tekan adjuster dengan SST untuk
menggerakan plunger naik turun 5 - 6 kali
Clean Engine Oil
– Prosedur penggatian oli
3. Plunger akan keras ketika plunger ditekan kuat
dengan tangan
• Ganti dengan yang baru, jika plunger bisa bergerak
walau olinya sudah diganti 3 kali
Sistem Pendinginan
Pendingin Mesin
TOYOTA Genuine Super Long Life

Tipe pendingin mesin
Coolant (SLLC) atau sejenis
Kapasitas [liters (US qts, Imp. qts)] 7.0 (7.4, 6.2)
Pemeriksaan Setiap 40,000 km (25,000 miles)
Jarak
Pertama 160,000 km (100,000 miles)
Maintenance
Penggantian
Berikutnya Setiap 80,000 km (50,000 miles)

Sistem Intake dan Exhaust
Keseluruhan
Main Muffler
Stainless Steel
Exhaust Manifold
Sub Muffler
Link-less Type Throttle Body
Resin Type Intake Manifold

Sistem Bahan Bakar
Keseluruhan
– Digunakan injector nozzle panjang dan quick connector
Long Nozzle 4-hole Pulsation Damper

Type Injector
Pressure
Regulator
Quick Connector
Fuel Filter
Quick Connector
Sistem Bahan Bakar
Injector
– Injector nozzle panjang digunakan untuk mengurangi
emisi gas buang dengan mencegah bahan bakar
menempel pada dinding intake
Approx.
25.9 mm
Long Nozzle Type Normal Type*
*Normal Type: 8.8 mm

Sistem Bahan Bakar
Keseluruhan
Quick Turn
[Quick Connector] Construction Fuel Cap
[Fuel Pump Module]
Pump
Steel Tank (55 L) Fuel
Motor
Sender
Gauge
Fuel
Filter
Sistem Pengapian
Keseluruhan
– DIS menggunakan 4 ignition coils (4 silinder)
– Digunakan busi tipe panjang
Long Reach Type Normal Type
DIS Spark Plug Spark Plug
Sistem Pengapian
Busi
– Busi panjang memperbaiki sistem pendinginan pada
kepala silinder (water jacket)
Extended
water Jacket
Long
Center Electrode: Long-reach Type Normal Type

Normal type
Sistem Pengapian
Busi
– Spesifikasi Busi
Supplier DENSO K20HR-U11
Jangkauan [Ref.: Tipe Normal] Sekitar 26.5 mm [19.0 mm]
Celah Busi 1.0 - 1.1 mm
Jarak Penggantian Setiap 20,000 km atau 24 Bulan

Keseluruhan
– Komponen asesories digerakan oleh serpentine belt,
single V type 7-ribbed belt
Power Steering
Idler Pulley Pump Pulley
No. 1
Alternator
Pulley Water Pump
Pulley
Air Conditioner
Compressor Pulley
Automatic
Tensioner
Crankshaft Idler Pulley

Pulley No. 2
Variasi Serpentine Belt
[Jarak Pemeriksaan Serpentine Belt]
berikutnya Setiap 20.000 km

Keseluruhan
Air Flow
Meter
Ignition Coil
with Igniter
Non-contact Type
Throttle Position Sensor
Water Temp. Sensor
Camshaft Flat Type

Position Sensor Knock Sensor
[Lainnya]
•32-bit Engine ECU
•Non-contact Type
Crankshaft Accelerator Pedal
Position Sensor Position Sensor
Flat type knock sensor
– Built-in open circuit detection resistor pada flat knock
sensor
Resistor
Piezoelectric
Element
2.5 V
5V
Resistor
NOTE: Saat open circuit, muncul DTC P0325 (baru)
Service Point (Engine Control System)
Flat type knock sensor
– Pasang knock sensor pada sudut tertentu (±10°)
Depan
10°
10°
ETCS-i (Electronic Throttle Control System-intelligent)
– Link-less type ETCS-i, untuk pengontrolan throttle
yang lebih baik (Non-linear control/Idle speed control)
Throttle Position
Accelerator Pedal Sensor
Position Sensor Throttle Control
Motor
Ignition Coil
Air Flow Meter Engine ECU
Fuel Injector
ETCS-i
– No-contact type throttle position sensor
Throttle Control Motor
Reduction Gears
Throttle
Valve
Throttle
Position Sensor
Hall ICs
Magnets
ETCS-i
– Throttle position sensor merubah densitas magnetic
flux menjadi electric signal
Magnet
Output Voltage (V)

VC 5 VTA2
VTA1
VTA
VC
ECM
E2 VTA2
VTA1
VTA
VTA2
E2
Hall 0
IC Full Close Full Open
Throttle Valve Opening Angle
Engine ECU
ETCS-i
– No-contact type Accelerator pedal position sensor
Magnets
Hall ICs Accelerator

Pedal Arm
ETCS-i
– Accelerator pedal position sensor merubah densitas
magnetic flux menjadi electric signal
VPA
Magnets
Output Voltage (V)

EPA 5
VPA2
VCPA
VPA2
VPA
Hall EPA2
0
ICs
Full Close Full Open
VCP2
Accelerator Pedal Depressed Angle
Engine ECU (ECM)
ETCS-i
– Fail-safe jika malafungsi pada accelerator pedal
position sensor
[Normal Condition] [Single Signal Failure] [Double Signal Failure]
Accelerator
Pedal Position
Sensor
Engine ECU Engine ECU Engine ECU
Full
Idle Idle Idle
Throttle Throttle
Position Control Motor
Sensor
ETCS-i
– Fail-safe jika malafungsi pada throttle valve position
sensor / motor / engine ECU / wire harness
[Normal Condition] [Fail-safe]
Accelerator
Pedal Position
Sensor
Engine ECU Engine ECU
Full Fixed
(6.5°)
Idle Idle
Throttle Throttle
Position Control Motor
Sensor
ETCS-i
– Fail-safe jika malafungsi pada throttle valve position
sensor / motor / engine ECU / wire harness
[Idling] [Full Acceleration]
Engine ECU Engine ECU
Retard 4 >> 2 Cylinder Normal 2 >> 4 Cylinder
Fixed Fixed
Idle Idle
VVT-i (Variable Valve Timing-intelligent) System
– VVT-i system di rancang untuk mengontrol intake
camshaft sehingga menghasilkan valve timing yang
sesuai dengan kondisi mesin
Camshaft Timing
Oil Control Valve
VVT-i Throttle
Controller Water Temp. Position
Sensor Sensor
Camshaft
Position Sensor Engine ECU
Air Flow
Meter
Crankshaft
Position Sensor
VVT-i System
– Controller terdiri dari housing yang digerakkan timing
chain dan vane yang bersatu dengan intake camshaft
Sprocket Intake Camshaft
Housing Lock Pin
Timing
Rotor
Vane (Fixed on Intake Camshaft)
[In Operation] [At a Stop]

Oil Pressure
VVT-i System
– Camshaft timing oil control valve mengontrol posisi
spool valve sesuai dengan duty control dari ECU mesin
To VVT-i Controller
(Advanced Side) (Retard Side)
Engine
ECU
Spool
Valve
Drain
Oil Coil Plunger
Pressure
Fitur Mesin 2TR-FE
Spesifikasi Mesin 2TR-FE
Model 1TR-FE 2TR-FE
Jumlah silinder & susunan 4-cylinder, In-line ←
16-valve, DOHC with VVT-i,
Mekanisme Katup ←
Chain Drive
Displacement [cm3 (cu. in.)] 1,998 (121.9) 2,694 (164.4)
Bore x Stroke [mm (in.)] 86.0 x 86.0 (3.39 x 3.39) 95.0 x 95.0 (3.74 x 3.74)
Rasio Kompresi 9.8 : 1 ←
Maximum Output
100 / 5,600 117 / 5,200
SAE-NET [kW / rpm]
Maximum Torque
182 / 4,000 242 / 3,800
SAE-NET [N·m / rpm]
Buka 0° ∼ 45° BTDC ←
Intake
Valve Tutup 64° ∼ 19° ABDC ←
Timing Buka 44° BBDC ←
Exhaust
Tutup 8° ATDC ←
Fuel Octane Rating 91 atau lebih ←
Tailpipe Emission Regulation  EURO II
5W-30 / API SJ, SL, EC
Oil Viscosity / Oil Grade ←
atau ILSAC
Fitur Mesin 2TR-FE
Perbedaan Utama dari Mesin 1TR-FE
1TR-FE 2TR-FE
Balance shaft  2 balance shafts
TWC  with
Fuel Tank Steel Resin
Injector Long nozzle 4-hole type Long nozzle 12-hole type
Starter P1.0 PS1.6
A/F, O2 Sensor  Planar type O2 with heater x 1

Fuel Pump Control
– Signal peledakan airbag dari airbag sensor assembly
dideteksi oleh ECU mesin, lalu meng-OFF circuit
opening relay
Ignition Switch EFI Relay
Circuit
Opening
Relay
Front Airbag Airbag GSW2 F/PS Engine
Sensors Sensor
ECU
(LH or RH) Assembly
Airbag not
deployed
Battery M
Airbag Voltage
deployed Fuel
Pump
Approx. 4 sec. Motor
Fitur Lain
Sistem Pengisian
– Segment Conductor type
alternator yang kompak
dan ringan
Tipe SE08
Rated Voltage / Output 12V / 80A
Supplier DENSO
Motor Starter
– Conventional planetary
reductionTipe
type starter P1.0
Rated Voltage / Output 12V / 1.0 kW
Supplier DENSO

Kijang Inova Bensin VVT I 160825125752

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Model Outline Mesin 1TR-FE Chassis Body Body Electrical

Resin Type Long Nozzle

[Low Tension Piston Rings]

2 Pieces Oil Ring

PVD: Physical Vapor Deposition

[Bearing Atas] [Bearing Bawah]

Bearing Atas Bearing Bawah

Oil Delivery Pipe

Roller Rocker Arm

Check Ball Spring

TOYOTA Genuine Super Long Life

Kapasitas [liters (US qts, Imp. qts)] 7.0 (7.4, 6.2)

Pemeriksaan Setiap 40,000 km (25,000 miles)

Berikutnya Setiap 80,000 km (50,000 miles)

Link-less Type Throttle Body

Resin Type Intake Manifold

Long Nozzle 4-hole Pulsation Damper

Long Nozzle Type Normal Type*

*Normal Type: 8.8 mm

[Fuel Pump Module]

Center Electrode: Long-reach Type Normal Type

Supplier DENSO K20HR-U11

Jangkauan [Ref.: Tipe Normal] Sekitar 26.5 mm [19.0 mm]

Celah Busi 1.0 - 1.1 mm

Jarak Penggantian Setiap 20,000 km atau 24 Bulan

Crankshaft Idler Pulley

[Jarak Pemeriksaan Serpentine Belt]

berikutnya Setiap 20.000 km

Water Temp. Sensor

Camshaft Flat Type

Throttle Control Motor

Output Voltage (V)

Hall ICs Accelerator

Output Voltage (V)

Engine ECU Engine ECU Engine ECU

Idle Idle Idle

Engine ECU Engine ECU

Engine ECU Engine ECU

Retard 4 >> 2 Cylinder Normal 2 >> 4 Cylinder

Sprocket Intake Camshaft

Housing Lock Pin

Vane (Fixed on Intake Camshaft)

[In Operation] [At a Stop]

Balance shaft  2 balance shafts

Fuel Tank Steel Resin

Injector Long nozzle 4-hole type Long nozzle 12-hole type

Starter P1.0 PS1.6

A/F, O2 Sensor  Planar type O2 with heater x 1

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