TOYOTA - Ficha de Calibración Bomba de Inyección - 1KZ - T

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

Objectives
Improve system knowledge
Learn DTC detection conditions
Implement structured and logic troubleshooting
procedures

Agenda
Date
Tue. 8 March
Wed. 9 March
Contents
Review system controls
Practice: case studies & review
Data list review and active tests

DTCs detection conditions & troubleshooting

procedures
Tue. 10 March
Test drive for CRD at Nagoya wharf center

Course summary & DPNR information
Q & A on VSC and CRD
Closing remarks
Fri. 11 March
History of Common-rail System

Common-rail Engines
1999
2000
2001
2002
2003
2004
2005
2006
1CD-FTV
1CD-FTV (D-CAT)
1KD-FTV
2KD-FTV
1ND-TV
2AD-FTV
2AD-FHV

Different variations on Common-rail
3 Generations
Diesel EFI
Common-rail
1st-generation
1st-generation
Common-rail
Common-rail
HP2
HP2 Supply
Supply Pump
Pump
Solenoid
Injector
Solenoid Injector
135 MPa
Max. Commonrail Pressure
2nd-generation
2nd-generation
HP3
HP3 Supply
Supply Pump
Pump
Discharge
Discharge Valve
Valve
Injector
Injector Compensation
Compensation
Code
Code
135 - 160 MPa
3rd-generation
3rd-generation
NSR
NSR +
+ DPNR
DPNR
Piezo
Piezo Injector
Injector
160 - 180 MPa

*: Data Matrix Code
Max.
Injector
Discharge
Common-rail Compensatio
Valve
Pressure
n
Model
Pump Type
Number
of SCV
NLP10
Bosch
Pressure
Regulating
Valve
160 MPa
A,B,C Mark
NDE120
Bosch
Pressure
Regulating
Valve
160 MPa
DMC*
CDT220, CLM20,
CDE120
HP2
No
135 MPa
Resister
CDT250, CUR10
HP3
Yes
160 MPa
QR Code
CDT250
HP3 + Flow
Damper
Yes
175 MPa
QR Code
KDJ90, KDJ12#
HP2
No
135 MPa
Resister
KDJ12# (04 -)
HP3
Yes
160 MPa
QR Code
KUN#6
HP3
No
160 MPa
QR Code
KLH1#,2#, KDN1##,
KDY2#0
HP3
Yes
135 MPa
Resister
KUN1#,25,35,
KDH20#,212,22#
HP3
No
160 MPa
QR Code
2AD-FTV
ADT251
HP3
No
167 MPa
QR Code
2AD-FHV
ADT251
HP3 + Flow
Damper
Yes
180 MPa
QR Code
Engine
1ND-TV
1CD-FTV
1CD-FTV
(D-CAT)
1KD-FTV
2KD-FTV

1st-generation
*: Data Matrix Code
Max.
Injector
Discharge
Valve
Pressure
n
Model
Pump Type
Number
of SCV
NLP10
Bosch
Pressure
Regulating
Valve
160 MPa
A,B,C Mark
NDE120
Bosch
Pressure
Regulating
Valve
160 MPa
DMC*
CDT220, CLM20,
CDE120
HP2
No
135 MPa
Resister
CDT250, CUR10
HP3
Yes
160 MPa
QR Code
CDT250
HP3 + Flow
Damper
Yes
175 MPa
QR Code
KDJ90, KDJ12#
HP2
No
135 MPa
Resister
KDJ12# (04 -)
HP3
Yes
160 MPa
QR Code
KUN#6
HP3
No
160 MPa
QR Code
KLH1#,2#, KDN1##,
KDY2#0
HP3
Yes
135 MPa
Resister
KUN1#,25,35,
KDH20#,212,22#
HP3
No
160 MPa
QR Code
2AD-FTV
ADT251
HP3
No
167 MPa
QR Code
2AD-FHV
ADT251
HP3 + Flow
Damper
Yes
180 MPa
QR Code
Engine
1ND-TV
1CD-FTV
1CD-FTV
(D-CAT)
1KD-FTV
2KD-FTV

2nd-generation
*: Data Matrix Code
Max.
Injector
Discharge
Valve
Pressure
n
Model
Pump Type
Number
of SCV
NLP10
Bosch
Pressure
Regulating
Valve
160 MPa
A,B,C Mark
NDE120
Bosch
Pressure
Regulating
Valve
160 MPa
DMC*
CDT220, CLM20,
CDE120
HP2
No
135 MPa
Resister
CDT250, CUR10
HP3
Yes
160 MPa
QR Code
CDT250
HP3 + Flow
Damper
Yes
175 MPa
QR Code
KDJ90, KDJ12#
HP2
No
135 MPa
Resister
KDJ12# (04 -)
HP3
Yes
160 MPa
QR Code
KUN#6
HP3
No
160 MPa
QR Code
KLH1#,2#, KDN1##,
KDY2#0
HP3
Yes
135 MPa
Resister
KUN1#,25,35,
KDH20#,212,22#
HP3
No
160 MPa
QR Code
2AD-FTV
ADT251
HP3
No
167 MPa
QR Code
2AD-FHV
ADT251
HP3 + Flow
Damper
Yes
180 MPa
QR Code
Engine
1ND-TV
1CD-FTV
1CD-FTV
(D-CAT)
1KD-FTV
2KD-FTV

3rd-generation
*: Data Matrix Code
Max.
Injector
Discharge
Valve
Pressure
n
Model
Pump Type
Number
of SCV
NLP10
Bosch
Pressure
Regulating
Valve
160 MPa
A,B,C Mark
NDE120
Bosch
Pressure
Regulating
Valve
160 MPa
DMC*
CDT220, CLM20,
CDE120
HP2
No
135 MPa
Resister
CDT250, CUR10
HP3
Yes
160 MPa
QR Code
CDT250
HP3 + Flow
Damper
Yes
175 MPa
QR Code
KDJ90, KDJ12#
HP2
No
135 MPa
Resister
KDJ12# (04 -)
HP3
Yes
160 MPa
QR Code
KUN#6
HP3
No
160 MPa
QR Code
KLH1#,2#, KDN1##,
KDY2#0
HP3
Yes
135 MPa
Resister
KUN1#,25,35,
KDH20#,212,22#
HP3
No
160 MPa
QR Code
2AD-FTV
ADT251
HP3
No
167 MPa
QR Code
2AD-FHV
ADT251
HP3 + Flow
Damper
Yes
180 MPa
QR Code
Engine
1ND-TV
1CD-FTV
1CD-FTV
(D-CAT)
1KD-FTV
2KD-FTV
System Overview
Common-rail System Diagram (for IMV)
NE Signal
G Signal
Various
Signals
Fuel Pressure
Sensor
Engine
ECU
EDU
Other Injectors
Pressure
Limiter
Common-rail
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
Common-rail
Supply Pump
SCV (Suction Control Valve)

Fuel Temp. Sensor
Fuel Pressure Sensor

Pressure Limiter
System Overview
Features of Common-rail System
Injection pressure, volume and

timing are controlled electrically
High accuracy engine control
High pressure fuel
Higher atomization of fuel
Stores high pressure fuel
High pressure injection in all

engine speed range
High performance and fuel economy

Low noise and vibration
Clean emission
System Overview
Difference from Common-rail and Conventional Diesel
Common-rail Diesel
Constant high pressure
Pressure
Common-rail
Sensor
System
SCV
EDU
Conventional Diesel
Instantaneously high pressure
Governor
Timer
ECU
Supply Pump
Injector
Pump
Injection
Nozzle
Injection Volume
Control
ECU (Injector)
Pump (Governor)
Injection Timing
Control
ECU (Injector)
Pump (Timer)
Injection Pressure
Control
Supply Pump (SCV)
According to rotational speed

and injection quantity
Pressurization
Supply Pump
Pump
Distribution
Common-rail
Pump
Injection Pressure
Max. 160 MPa
Approx. 15 MPa
System Overview
Sensors and Actuators
Air Flow Meter
Intake Restrictor
Valve (Step Motor)
Atmospheric
Temp. Sensor
Intake Air
Temp. Sensor
E-VRV (for EGR

Valve Control)
Turbo Pressure
Sensor
VSV (for EGR

Valve Close)
Camshaft
Position Sensor
Injector
Crankshaft
Position Sensor
VSV (for Turbo

Pressure Sensor)
Glow Plug
Water Temp.
Sensor
Illustration is for 1CD-FTV on CDE120
ECD System Components (DENSO)

Supply Pump
Supplies the high pressure fuel to the common-rail
HP2
HP3
Type
HP2 (Outer Cam)
HP3 (Inner cam)
Generation
1st
2nd/3rd
SCV
2 (Time controlled)
1 (Duty-cycle)
Plunger
4 (Radial Type)
2 (Opposite type)
Weight [g (lb.)]
6040 (13.32)
3800 (8.38)

Supply Pump (HP2)
Construction and operation
Click!
Movie

Supply Pump (HP2)
Suction and pumping operation
To Fuel Tank
SCV1
Feed Pump
SCV2
To
Common-rail

Supply Pump (HP2)
Suction control
Not Active
SCV1
Active
SCV2

Supply Pump (HP3)
Construction
Check
Valve
Eccentric and
Ring Cam
Plunger
Delivery
Valve
Feed
Pump
Fuel Temp.
Sensor
SCV (Suction
Control Valve)

Supply Pump (HP3)
Construction
To fuel tank (return)
Ring Cam
Plunger
Eccentric
Cam

Supply Pump (HP3)
Fuel flow
To common-rail
From fuel
tank

Supply Pump (HP3)
Fuel flow
Click!
Movie

Supply Pump (HP3)
Plunger A: Suction
Plunger B: Pumping
Plunger A: Pumping
Plunger B: Suction
Check
Valve
Plunger A
SCV
Plunger B
: From Feed Pump
: To Common-rail

Supply Pump (HP3)
Click!
Movie

Supply Pump (HP3)
Fuel control operation (SCV opening small)
SCV fixed opening during suction stroke
Fuel
Pumping
Mass

Supply Pump (HP3)
Fuel control operation (SCV opening large)
Fuel
Pumping
Mass

Supply Pump (HP3)
Fuel control operation (SCV opening small)
Click!
Movie

Supply Pump (HP3)
Fuel control operation (SCV opening large)
Click!
Movie

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
Engine ECU
Crankshaft
Position Sensor
Accelerator Pedal
Position Sensor

Supply Pump
SCV signals
HP3
HP2

Common-rail
Stores high pressure fuel and supplies to injector
[Three kinds of common-rail]
Pressure
Limiter
Fuel Pressure
Sensor
Pressure
Discharge
Valve
Pressure
Limiter
Common-rail Pressure
Pressure
Discharge Valve
Fuel Pressure
Sensor
Engine Stop
Idling Full Load
Gradually become 0 MPa
20 180* MPa
*: Depending on the engine types or generations

Common-rail
Fuel pressure sensor (PCR)
Detects the fuel pressure in common-rail and
provides feedback
To Injector
From Supply Pump
Common-rail
[Fuel Pressure Sensor]

Sensor Tip
Common-rail
Pressure
Pressure
Limiter

Common-rail
Fuel pressure sensor (PCR)
Output Voltage (V)
Output characteristic
4.2
1.0
0
160
Common-rail Pressure (MPa)

Common-rail
Fuel pressure sensor (PR, PR2)
With 2 different circuits for
Sensor
Tips
Output Voltage (V)
Output characteristic
: Common-rail Pressure
4.44
3.89
1.40
0.85
PR (Main)
PR2 (Sub)
0
190
Common-rail Pressure (MPa)

Common-rail
Pressure discharge valve
To control fuel pressure to target injection pressure
[Valve Close]
[Valve Open]

Common-rail
Pressure discharge valve
[without Discharge Valve]
Accelerator
Pedal Opening
Angle
Sudden
Deceleration
[with Discharge Valve]

Sudden
Deceleration
Injector
Injection
Operation
Pressure Limiter
Opening Pressure
Common-rail
Pressure
Actual CR
Pressure
Target CR Pressure
Actual CR
Pressure
Target CR Pressure

Injector
High pressure injection for higher atomization
Solenoid
Coil
From
Common-rail
Control
Chamber
Solenoid
Coil
Return to
Fuel Tank
Nozzle
Spring
Click!
Movie
Injector Hole
Injector Pressure
Voltage
Nozzle
Needle
Piston
Nozzle
Spring
6 or 8
135 180 MPa
150 V
Nozzle
Needle

Injector
Small injection hall (0.14 mm)
[Top of Injector]
0.14 mm
Click!
Movie

Injector
Difference in the injection of gasoline and common-rail
[Gasoline Engine]
[Common-rail Engine]
Engine
ECU
Engine
ECU
Constant Low
Pressure
[Approx. 0.3 MPa]
EDU
Variable High
Pressure
[30 160 MPa]
Injection Volume
Injection
Volume
High
Long
Electricity Time
Electricity Time
Common-rail
Pressure

Injector
Injection volume correction
To correct injection quantity and injection timing
Correction
Resistor
Correction
Resistor
Engine
ECU
EDU
Solenoid
Coil
1CD-FTV
Injector

Injector
There are 25 kinds of correction resistance
[Resistance ()]
Correction
Quantity
High
Pressure
Side
Correction
Quantity
Low Pressure Side Correction Quantity

-5S
-2S
0S
2S
5S
-4S
31
41
54
68
85
-2S
240
200
160
130
105
0S
300
365
440
550
665
2S
1910
1540
1240
1020
825
4S
2370
3010
4020
5760
9530

Injector
Injector compensation code
Injector
Compensation Code
QR Code
Injection Quantity
Compensation Code Type (QR Code)
Activation Pulse Correction TQ

Laser Marking
: Correction Point

Injector
Difference between compensation code and one fixed
resistance value
Compensation Code Type (QR Code)

Injection Quantity
Injection Quantity
Correction Resister Type

: Correction Point

EDU (Electric Driver Unit)
[for Resister Type]
Voltage
150V
0V
Engine ECU
Time
#1
IJT#1
INJ#1
#2
IJT#2
INJ#2
#3
IJT#3
#4
IJT#4
INJF
RINJ1
RINJ2
RINJ3
RINJ4
IJF
EDU
INJ#3
INJ#4
COM1
Injectors

Voltage
EDU
Battery
EDU
+B
150V
0V
COM1
High
Voltage
Generation
Circuit
High
Voltage
IJT#1
IJT#2
IJT#3
IJT#4
Engine
ECU
Time
INJ#1
Control
Circuit
INJ#2
INJ#3
INJ#4
IJF
GND
GND

EDU
Injector drive signals
IJT#1
IJF
COM1
INJ#1

Overview ECU Inputs
Basic Parameters
Crankshaft Position Sensor (Ne)
Accelerator Pedal Position Sensor (VA)
Injector
Correction Parameters
Intake Air Temp. Sensor (THA)
EDU
Water Temp. Sensor (THW)

Fuel Temp. Sensor (THF)
Air Flow Meter (VG)
Turbo Pressure Sensor (PIM)
Vehicle Speed Sensor (SPD)
Fuel Pressure Sensor (PCR)
Engine
ECU
EGR Valve
Ignition Switch (STA)

Blower Switch (BLW)
A/C Amplifier (AC)
Alternator (ALT)
DLC3

Overview ECU Outputs
Injector (Timing and duration)

Pressure Discharge Valve
Suction Control Valve
Various Sensor
EDU (Power supply)
Engine
ECU
Intake Restrictor Valve

VN Turbo (Nozzle vane control)
Glow Plug
EGR Valve
DLC3

Crankshaft Position Sensor

Accelerator Pedal Position Sensor (VPA, VPA2)
Magnets
Hall
ICs

Air Flow Meter [Hot Wire Type] (VG)
Temp.
Sensing
Element
Intake Air
Temp. Sensor
Platinum Hot
Wire Element

Turbo Pressure
Sensor
Engine
ECU
VSV (for Turbo
Pressure Sensor)

EGR System
System diagram
Position Sensor
Intake
Restrictor
Valve
Intake Restrictor
Valve Control Motor
EGR Valve
Position
Sensor
Engine
ECU
Vacuum
Pump
Vacuum
Damper
EGR Valve
Engine
E-VRV
(for EGR valve control)
Atmospheric
Pressure
Sensor
Crankshaft
Position Sensor
Accelerator Pedal
Position Sensor
Water Temp.
Sensor
Turbo Pressure
Sensor
Intake Air Temp.
Sensor

EGR System
EGR valve (Step Motor Type)
EGR Valve
(Step Motor)
To Intake
Manifold
EGR
Valves
From
Exhaust
Manifold

EGR System
EGR valve (Linear Solenoid Type)
EGR Valve
Position
Sensor
Linear
Solenoid
EGR
Valves
To Intake
Manifold
From
Exhaust
Manifold

EGR System
Intake Restrictor Valve (Step Motor Type)
Air Out
Reduction Gears
Intake
Restrictor Valve
Air IN
Step Motor
Throttle Valve Fully Opened Switch

EGR System
Intake Restrictor Valve (Rotary Solenoid Type)
A quick response and high precise are realized by
driving a direct valve shaft

Position Sensor
Rotary Solenoid Type

Torque Motor
Magnet
Steel Layer
Hall IC
Magnet
Magnet

EGR System
Intake Restrictor Valve (Rotary Solenoid Type)
Intake restrictor shutter valve position sensor
Magnet
Output Voltage (V)
Hall IC
VC
Engine
ECU
VLU
E2
5
3.51
1
0.71
0
20
0
(Full Close)
Intake Shutter
Valve Position
Sensor
70
(Full Open)
Intake Shutter Valve

Opening Angle (deg)
100

Variable Nozzle Vane Type Turbocharger
Exhaust
Gas
Step
Motor
Intake
Air
Link
Nozzle Vane

Exhaust
Gas
DC Motor
Intake Air
Nozzle Vane
Position Sensor
Reduction
Gears
Turbine
Wheel
Nozzle Vane
Motor Rod
Link
Full-Close
Stopper

Operation
Click!
Movie

Nozzle Vane Position Sensor
Non-contact type position sensor
Hall ICs
Magnets
Cross-section
0
-55
55
Output Voltage (V)
Output characteristic of
main, sub sensor
4.5
pe
O
VN
2.5
0.5
-55
Cl o
N
V
se
0
55
Sensor shaft rotation angle ()
ECD System Components (BOSCH)

Main Components for Common-rail System
Shown for the 1ND-TV engine on the YARIS
Fuel
Pressure
Sensor
Injector
Supply
Pump
Common-rail
Fuel Pressure
Regulator

Supply Pump
Construction
3-plunger type that have 2-funciton of fuel suction
and fuel delivery
Delivery Valve
Plunger
Check Valve
Outer Cam
Inner Cam
Feed Pump
MPROP
(Magnetic Proportional Valve)

Supply Pump
Fuel flow
From Fuel Tank
MPROP
Outer Cam
To MPROP
Inner Cam
Feed Pump

Supply Pump
Fuel flow
To Common-rail
To Plunger
Plunger
MPROP
Inner Cam
Outer Cam

Supply Pump
Basic suction and pumping operation is the same as
HP3 supply pump
Plunger A: Pumping Finish
Plunger B: Pumping Start
Plunger C: Suction
Check Valve
Outer
Cam
Plunger
A
Plunger
C
MPROP
Plunger
B
Inner
Cam
Plunger A: Suction
Plunger B: Pumping Finish
Plunger C: Pumping Start

Common-rail
Basic operation is the same as the DENSO type
with fuel pressure sensor and fuel pressure regulator

Common-rail
Fuel pressure control
Accelerator Pedal
Position Sensor (VPA)
Crankshaft Position
Sensor (Ne)
Calculation of
Target Injection
Volume
Engine ECU
MPROP
Fuel
Pumping
Common-rail
Fuel
Discharge
Fuel
Pressure
Regulator

Injector
Three kinds of identification mark (A, B or C) to
compensate for tolerances of injection of each injector
Identification
Mark

Atmospheric pressure sensor
Atmospheric pressure is measured by sensor built in
the engine ECU
Atmospheric Pressure Sensor

EGR System
EGR valve
To
E-VRV
EGR Valve
To
Intake
Manifold
From
Exhaust
Manifold
EGR Valve

EGR System
Intake restrictor valve
Actuator
Intake
Restrictor Valve
EGR Passage
Common-rail Control Systems

Overall
Consists mainly two parts, fuel metering part and fuel
supply part
[Electrical Part]
Various Sensor
Injection Volume Control

Injection Timing Control
Idle Speed Control
Fuel Pressure Control
Engine ECU
Injection rate Control

Turbo Control
EGR Control
Glow Control
Diagnosis
EDU
Supply Pump
Common-rail
[Mechanical Part]
Injector

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
Fuel
Pressure
Basic Injection
Volume
EDU
Comparison
Maximum
Injection
Volume
Compensation
Value
Decision on
Duration
Injector
Feedback Value
Engine ECU
Injector

Basic injection volume
Accelerator Pedal
Crankshaft Position
Sensor (Ne)
Basic Injection
Volume
(Map Data in ECU)
+
Basic Injection
Volume Correction
Engine ECU
Clutch Switch (CLSW)

ISC* Correction
*: Idle Speed Control

Basic injection volume
[Basic Injection Volume Pattern]

: Amount of Accelerator
Pedal Effort (VPA)
Basic
Injection
Volume
100%
(Full Load)
50%
10%
20%
30%
Idle
Engine Speed

Maximum injection volume
Crankshaft Position
Sensor (Ne)
Overheating Protection
Fuel Temp. Sensor (THF)
Basic/Maximum
Injection Volume
(Map Data in ECU)
Maximum
Injection Volume
Correction
Engine ECU

(PC, VPC)
Air Flow Meter (VG)
Intake Air Mass

Maximum injection volume
[Maximum Injection Volume Pattern]

Injection
Volume
Intake Air
Volume-large
Varies by
Required Volume
Intake Air
Volume-small
Engine Speed

Final injection volume decision
Case of VPA 30% Selects basic injection volume
[Determining Injection Volume]
Injection
Volume
: Basic Injection Volume

: Maximum Injection Volume
Selects lowest
30% VPA
Engine Speed

Final injection volume decision
Case of VPA 100% Selects Max. injection volume
[Determining Injection Volume]
Injection
Volume
: Basic Injection Volume

: Maximum Injection Volume
Selects
lowest
100% VPA
Engine Speed

Injection volume correction by intake air
[Intake Air Pressure Correction]

Pressure Correction
[Intake Air Temp. Correction]
Overload Protection
Increase
Correction
Coefficient
1
Correction
Coefficient
Decrease
1
Decrease
3
Turbo Pressure Sensor Output (V)
40
Intake Air Temp. (deg)

Injection volume correction by fuel temperature
[Fuel Temp. Correction]
Increase
Correction
Coefficient
1
Decrease
40
Fuel Temperature (deg)

Injection volume correction by water temperature
[Water Temp. Correction]
Increase
Correction
Coefficient
40
Water Temperature (deg)

Injection duration
Decides opening time of injector
by final injection volume
NE Signal
G Signal
Engine
ECU
Controls opening
timing of injector
EDU
Various
Signals
Common-rail
From
Supply Pump
Pressure
Limiter
Injector

Injection duration
Fuel
Pressure
Basic Injection
Volume
Comparison
Volume
Maximum
Injection
Volume
INJ Time
Calculation
Injector
Compensation
Value
EDU
Injector
Feedback Value
Engine ECU
Injector

Injection volume control during starting
Increase
Correction
Coefficient
Starting Injection Volume

Basic Injection
Volume
1
40
Water Temperature (deg)
Corrections
Water Temp. Sensor

Engine ECU

Fuel Injection Timing Control
Basic injection timing
(injection timing control after started)
Accelerator Pedal
Crankshaft Position
Sensor (Ne)
Basic Injection Timing
+
Injection Timing
Correction
Engine ECU

EDU
Injector

Injection timing control during starting

(Ne)
Target Injection
Timing Correction

Engine ECU

Injection timing corrections
Target injection timing = Basic timing + corrections
[Intake Air Pressure Correction]
[Basic Target Injection Timing]
BTDC
(deg)
: Amount of Accelerator
Pedal Effort (VPA)
: Engine Speed
Timing
Advance
(CA)
High rpm
Low
rpm
Full Load
Intake Air Pressure (PIM)
[Water Temp. Correction]
15
Light Load
: Water Temp.
Timing
Advance
(CA)
COLD
HOT
Engine Speed (rpm)

Engine Speed (rpm)

Idle Speed Control
Target idle speed control
Accelerator Pedal Position

Sensor (VPA)
Target Engine Speed
Calculation

A/C Amp. [Idle-up Signal] (ACT)
Comparison
Injector
Volume
Correction
Actual Engine
Speed
Engine ECU
Electric Load

Idle Speed Control
Feedback correction
Idle speed fluctuations are detected by comparing
t values
360CA
Crankshaft Position
Sensor Signal (Ne)

Target injection fuel pressure
[Fuel Pressure Control]
Fuel Pressure
Sensor
SCV
Controls
SCV
opening
Common-rail
pressure
(Feedback)
Calculation of
target injection
pressure
Engine ECU
Crankshaft
Position Sensor
Accelerator Pedal
Position Sensor

Target injection fuel pressure
To control target fuel pressure in common-rail by
SCV or pressure discharge valve
: Calculated Final Injection Volume

MAX
Target Injection Fuel
Pressure
MIN
Engine Speed (rpm)

Injection Rate Control
Injection rate control
TDC
Small Injection
Amount Prior to
Ignition
Combustion
Process
Injection
Rate
Heat
Generation
Rate
High
Injection
Rate
Improvement [Pilot Injection]
Heat Large
Pre-mixture
Combustion
(NOx, Noise)
Ignition Delay
[Delta Injection]
Small
Pre-mixture
Combustion

Pilot injection
Accelerator Pedal
Crankshaft Position
Sensor (Ne)
Basic Pilot Timing

Correction
Pilot Injection
(Volume, Timing, Interval)
Engine ECU
EDU
Injector

Main injection timing
Camshaft Position
Sensor Signal (G)
Injection Timing
Pilot Injection
Fuel Quantity
Main
Injection

Other System Operation
Intake restrictor valve control system
Reduction Gears
Air Out
Intake
Restrictor Valve
Air IN
Step Motor
Throttle Valve Fully Opened Switch

Intake restrictor valve control system
Intake Restrictor
Valve Control
Motor
Engine
ECU
Intake Restrictor
Valve Position
Sensor

(Ne)
Intake Air Temp. Sensor
(THA)
Accelerator Pedal Position
Sensor (VPA)
Intake
Restrictor Valve


Turbocharger control system
Turbo Pressure
Sensor
DC Motor
Atmospheric
Pressure Sensor
Nozzle Vane
Position
Sensor
Actual
Nozzle
Vane
Position
Crankshaft
Position Sensor
Nozzle
Vane
Position
Control
Turbo Motor
Drive
Engine
ECU
Water Temp.
Sensor
Intake Air
Temp. Sensor
Target Nozzle Vane

Position Signal
Turbocharger Control Status
After Glow Time (sec.)

Glow control system
Ignition ON
Switch
OFF
120
Glow
Plug
20
(68)
40
(104)
Engine Coolant Temp. [C (F)]
Engine
Speed
(rpm)
ON
OFF
After Glow Time
0
Starting Engine

TOYOTA - Ficha de Calibración Bomba de Inyección - 1KZ - T

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TOYOTA - Ficha de Calibración Bomba de Inyección - 1KZ - T

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Common-rail Diesel

High-tech Diagnosis Course for Common-rail

High-tech Diagnosis Course for Common-rail

High-tech Diagnosis Course for Common-rail

Data list review and active tests

DTCs detection conditions & troubleshooting

Test drive for CRD at Nagoya wharf center

History of Common-rail System

History of Common-rail System

135 - 160 MPa

160 - 180 MPa

History of Common-rail System

History of Common-rail System

*: Data Matrix Code

History of Common-rail System

*: Data Matrix Code

History of Common-rail System

*: Data Matrix Code

Fuel Inlet Pipe

SCV (Suction Control Valve)

Fuel Pressure Sensor

Injection pressure, volume and

High accuracy engine control

High pressure fuel

Higher atomization of fuel

Stores high pressure fuel

High pressure injection in all

High performance and fuel economy

Supply Pump (SCV)

According to rotational speed

Max. 160 MPa

Air Flow Meter

E-VRV (for EGR

VSV (for EGR

VSV (for Turbo

Illustration is for 1CD-FTV on CDE120

ECD System Components (DENSO)

HP2 (Outer Cam)

HP3 (Inner cam)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

: From Feed Pump

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

ECD System Components (DENSO)

Idling Full Load

Gradually become 0 MPa

*: Depending on the engine types or generations

ECD System Components (DENSO)

From Supply Pump

[Fuel Pressure Sensor]

ECD System Components (DENSO)