Professional Documents
Culture Documents
Rail
• Pressure sensor
Supply pump • Pressure limiter
•SCV
•Fuel temperature
1
Fuel System
Diagram Konstruksi Supply Pump
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Fuel System
Plunger
Regulating valve
Drive
shaft Filter
Plunger
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Fuel System
Fuel flow dalam supply pump
The fuel that is draw from the fuel tank passes through the
route in the supply pump as illustrated, and is fed into the rail
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Fuel System
Fuel pump (DENSO type HP3)
Plunger A
Ring cam
Feed pump
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Fuel System
Konstruksi
Plunger
Eccentric Cam
Ring cam
camshaft
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Fuel System
Operation
Movie
Fuel System
Konstruksi Feed Pump
The trochoid type feed pump, which is integrated in the supply pump, draws
fuel from the fuel tank and feeds it to the driven by the drive shaft
Quantity
decrease Quantity decrease (fuel discharge
Outer rotor
Inner rotor
Intake port
Discharge Quantity Quantity increase (Fuel intake)
port increase
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Fuel System
Suction Control
Valve
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Fuel System
In case of short time ON duty Feed pump
Large valve
Short time Large valve open
ON duty opening
Movie 10
Fuel System
In case of long time ON duty Feed pump
Plunger
Minimum intake quantity
Small valve
Long time Small valve opening
ON duty opening
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Fuel System
Injector Structure and System
Movie
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Fuel System
Injector Structure and System
Movie
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Fuel System
Injector OFF ON
Operation
Hydraulic
Electro magnetic pressure
Hydraulic valve
pressure
20 to 180MPa 20 to 180MPa
Orifice
Orifice
Nozzle
Movie
Fuel injection 14
Fuel System
Fuel injection control
1. Fuel injection amount control
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Fuel System
Fuel injection control
2. Fuel injection timing control
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Fuel System
Fuel injection control
2. Fuel injection timing control
EX.) Multiple stage injection control for 4M41 DID
Pre Injection
Main Post
Opening of Injection face
Injection Injection
Pilot After
Injection Injection
Time
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Fuel System
Fuel injection control
3. Fuel pressure control
System Configuration Diagram
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Fuel System
Fuel injection control
4. Idle speed control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed,
and controls the fuel injection amount so that the actual idle speed will
attain the target idle speed (feedback control).
Furthermore, the following compensations are added to control the engine
at a stable idle speed.
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Fuel System
Fuel injection control
5. Throttle valve control
System Configuration Diagram
When engine is Engine-ECU actuates the throttle valve control servo to fully open the throttle
running valve. In a driving range in which the exhaust gas recirculation control is being
effected, the throttle valve closes to create a vacuum in the inlet manifold.
When engine is Engine-ECU actuates the throttle valve control servo to fully close the throttle
stopped valve for 3 seconds. This cuts off the flow of intake air and prevents the engine
from run on (dieseling).
When a problem If the engine-ECU detects a serious problem, it immediately closes the throttle
develops valve fully to stop the engine.
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Fuel System
Sensor
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Fuel System
Fuel filter
High cleaning
efficiency filter
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Fuel System
Fuel tank
Mounted on the front of the rear axle to reduce the shock during impact
Materials without lead and hexavalent chromium have been employed for the fuel
tank with attention to environmental issues.
A fuel cut valve, which prevents fuel leakage when the vehicle banks or rolls over,
has been located inside the fuel tank for fewer openings and hose bonding points24
on the fuel tank top surface.
Fuel System
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (S,Q.L.) at the
end of line (E.O.L) check S.Q.L start and S.G.L end by MIL status as follow.
Procedure for Small quantity learning When injector is changed or
Precondition correction has to be applied
1. Vehicle speed : 0km/h to ECU for all cylinder before
automatic learning mode
2. Accelerator pedal: Fully close
3. Power steering : not operated
4. Electric load : Off S.Q.L
5. Water temp. : 80 deg. or higher S.Q.L start complete
Idling 6. AT oil temp. : 60 deg.or higher
7. Oil temperature: 30 deg. or higher MIL: Blink MIL: Off
8. Shift position: N or P
9. A/C : Off
10. Idle condition: stable S.Q.L NG
When injector is
changed 25
Fuel System
Common rail engine learning function
After fuel-related parts are replaced, the common rail engine must register their
identification codes with the engine-ECU and execute learning.
26
Fuel System
1. Common rail relative parts supply unit
Supply unit Components caution After replacement
Supply pump Suction control valve Replace supply pump Initialize learned value
Ass’y Fuel temperature sensor ass’y when changing by MUT-III
Supply pump parts
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Fuel System
2. Caution and method of Injector correction(1/2)
1) There are correction value, QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
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Fuel System
2. Caution and method of Injector correction(2/2)
2) Make sure the replace injector cylinder No.
(because it can not detect cylinder No. mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is no/partial value registered in ECU)
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Fuel System
3. Diagnosis function
Increase diagnosis items (CDI: Approx.100 items , IDI:Approx.30items)
Ex) New diagnosis items
Diagnosis items Diagnosis Failure parts Remarks
code
Fuel leakage P0093 Fuel pipe Suction control valve duty amount
too big against requirement 30
Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
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Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
Select the write mode from the menu, enter the identification
Code printed on the injector, and execute writing.
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Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
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Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
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Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
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Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
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Fuel System
Common rail engine learning function
1. Injector identification code registration procedure
37
Fuel System
Common rail engine learning function
Purpose : To keep emission and noise level at adequate levels, the engine-ECU
must learn Injector fuel injection in idle mode.
During learning, the engine-ECU calculates actual injection from each cylinder
based on changes in engine speeds and corrects pilot injection control. It then
keeps records of this amount of correction as a learned value.
For this reason, after the engine-ECU or injector is replaced, learning must be
executed using the MUT-III.
Caution
If small injection quantity learning has not been executed,
the engine warning lamp blinks.
38
Fuel System
Common rail engine learning function
2. Small injector quantity learning procedure
- Engine coolant temperature : 80 – 90ºC
- AT temperature : 60ºC or higher
- Lamps, A/C condenser fan and accessories : OFF
- Transmission : Neutral
- Power steering : Static state
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Fuel System
Common rail engine learning function
2. Small injector quantity learning procedure
40
Fuel System
Common rail engine learning function
3. Supply Pump Correction Learning procedure
Purpose : To engine-ECU learns the relation between the suction control valve (linear
Solenoid valve) of the supply pump drive current and the fuel injection volume.
The learning value is calculated from the suction control valve drive current and the rail
pressure sensor output voltage.
When the supply pump is replaced, therefore, this learning must be executed.
Re-learning is executed when the engine is idling after the learning value in the engine-ECU
Has been reset by the MUT-III.
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Fuel System
Common rail engine learning function
3. Supply Pump Correction Learning procedure
42
Fuel System
Common rail engine learning function
3. Supply Pump Correction Learning procedure
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Service Detail
Initialization setting value for Supply pump.
Initialization setting
value
Setelah mengganti komponen harus dilakukan setting initialisasi dengan kondisi IG switch OFF
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Service Detail
Bagaimana mengganti Common Rail ? Common Rail tidak dapat
dibongkar menjadi komponen yang terpisah ( harus diganti secara
assy )
Tidak dapat
Pressure Sensor
dibongkar !
Pressure
Limiter
45
Service Detail
Bagaimana cara memasukan QR code untuk injector
baru.Saat mengganti Injector atau ECU , harus memasukan
kembali QR Code dari Injector .
ganti Injector QR code baru
New data
Engine ECU
Re - Input
ganti ECU
semua 4 Injectors
46
Service Detail
Bagaimana memasukan QR code pada Injector
Saat mengganti ECU
Saat mengganti Injector
Save data to MUT –3 Tester
mengganti Injector
Data saving
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Injector ID
Procedure
Penggantian Injector
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Injector ID
Procedure
Penggantian ECU
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Supply Pump Initialization
Procedure
PRASYARAT :
- Engine coolant temperature : 60ºC atau lebih tinggi
- Fuel temperature : 30ºC atau lebih tinggi
- Accelerator pedal : OFF
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Service Detail
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector Injector Seal
O-Ring
Washer Cylinder head cover
Gasket
O-Ring
Part-part Mengganti
yang diganti pipa baru
*Injector Discharge
•*Rail pipe
•*Supply
pump Inlet pipe
•*Rail
Inlet pipe
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COMMON RAIL SYSTEMS
86
Service Detail
Procedure for fuel line replacement should be operated with attention to the cautionary statement.
The contents of “CAUTION” is the same as L200 4D56’s. (see below)
87
Service Detail
Memeriksa kebocoran (Fuel System)
1. IG switch OFF
No leakage
2. Engine Start
No leakage
No leakage
Normal Fuel System
88
Service Detail
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Active Test
•Injector Cut #1
•Injector Cut #2 High voltage
•Injector Cut #3
•Injector Cut #4
89
Service Detail
Penggantian Fuel Filter Hand pump
Fuel filter
Warning switch
To supply pump
Filter
Water level
warning switch
90
Service Detail
Fuel Filter Structure
Water level
warning switch
91
Service Detail
Fuel Filter Warning Lamp Tersumbatnya Fuel filter akan dideteksi
dengan Fuel filter warning switch
Fuel filter warning
switch Fuel Filter
warning lamp
tersumbat
Combination meter.
Saat Fuel filter terdapat beberapa masalah maka Fuel warning lamp
Fuel Filter akan menyala
92
Service Detail
Fuel Filter Warning Lamp Diagram
Combination meter
To Supply pump
Filter
Water level
warning 1
Flashing
Fuel Filter
warning 2
Showing
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Service Detail
Fuel Filter Warning Lamp Diagram
Ketika Fuel filter warning lamp menyala, berarti perlu untuk mengganti filter dan reset warning
lamp
Mengganti filter
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Service Detail
Fuel Filter Warning Lamp Diagram
Melepas Filter
lepas Inlet hose
lepas Outlet hose Fuel level
lepas Connector
Drain plug
Drain water
96
Service Detail
Fuel Filter Warning Lamp Diagram
97
Service Detail
Fuel Filter Warning Lamp Diagram
Install fuel filter / Reset warning lamp
Within
3 – 60 sec. 3 sec.
IG ON
OFF
98
Service Detail
Fuel Filter Warning Lamp Diagram
Finish
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