Fuel System

Gambaran Umum Common Rail System Lokasi Part Fuel pipe to

Front Engine Injector

injector

Fuel pipe to Rail

Rail Pressure sensor Pressure limiter •

Supply pump SCV Fuel temperature

•

•

•

1

Fuel System Diagram Konstruksi Supply Pump

2

Fuel System Konstruksi Supply Pump

SCV Plunger

Pump body

Feed pump Fuel temperature sensor

Ring cam

Regulating valve Drive shaft

Filter Plunger

3

Fuel System Fuel flow dalam supply pump

The fuel that is draw from the fuel tank passes p asses through the route in the supply pump as illustrated, and is fed into the rail

4

Fuel System Fuel pump (DENSO type HP3) The eccentric camshaft is attached to the camshaft. The eccentric cam is connected to the ring cam camshaft Plunger A Ring cam Eccentric Cam

Ring cam

Feed pump The plunger and the suction valve are attached to the ring cam. The feed pump is connected to the rear of the come shaft

Plunger B 5

Fuel System Konstruksi Plunger

Eccentric Cam Ring cam

camshaft

6

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 Outer rotor

Quantity decrease (fuel discharge

Inner rotor

Intake port Discharge port

Quantity increase

Quantity increase (Fuel intake)

8

Fuel System Suction Control Valve

9

Fuel System In case of short time ON duty Plunger

Short time ON duty

Feed pump

Maximum intake quantity

Large valve opening

Large valve open Movie

10

Fuel System In case of long time ON duty Plunger

Long time ON duty

Feed pump

Minimum intake quantity

Small valve opening

Small valve opening 11

Fuel System Injector Structure and System An injector consists of a nozzle, command piston, command chamber, and solenoid valve that controls the ON/OFF of the outflow orifice. The command piston moves vertically in accordance with the fuel pressure in the command chamber. chamber. As the nozzle is integrated with the command piston, the orifice of the injector opens and closes with the vertical movement of the command piston.

Movie

12

Fuel System Injector Structure and System

Movie

13

Fuel System Injector Operation Hydraulic pressure

OFF

ON Electro magnetic valve

Hydraulic pressure

Spring force 20 to 180MPa

Spring force 20 to 180MPa

Orifice

Orifice

Nozzle Movie

Fuel injection

14

Fuel System Fuel injection control 1. Fuel injection amount control

Basically, Basically, the fuel injection amount is calculated in accordance with the accelerator position and the engine speed. 15

Fuel System Fuel injection control 2. Fuel injection timing control

Basically, Basically, the fuel injection timing is calculated in accordance with the engine speed and the target injection amount. 16

Fuel System Fuel injection control 2. Fuel injection timing control Multiple stage injection control

Engine-ECU injects fuel before and after the main injection to suit the driving conditions. The injection that takes place before the main injection is called pre-injection, which is provided primarily for reducing combustion noise and NOx. The injection that takes place after the main injection is called after-injection, after-injection, which is provided primarily for activating the catalyst.

17

Fuel System Fuel injection control 2. Fuel injection timing control EX.) Multiple stage injection control for 4M41 DID

Pre Injection e c a f n o i t c e j n I f o g n i n e p O

Main Injection

Post Injection After Injection

Pilot Injection

Time 18

Fuel System Fuel injection control 3. Fuel pressure control System Configuration Diagram

Engine-ECU maintains maintains a high fuel pressure by controlling the rail pressure in accordance with w ith the signals input from various sensors. Accordingly, Accordingly, the injection of fuel at a high pressure improves combustion and reduces the amount of discharge of the particulate matter. 19

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 w ill attain the target idle speed (feedback control). Furthermore, the following compensations are added to control the engine at a stable idle speed. 20

Fuel System Fuel injection control 5. Throttle valve control System Configuration Diagram

When engine is running

Engine-ECU actuates the throttle valve control servo to fully open the throttle valve. In a driving range in which the exhaust gas recirculation control is being effected, the throttle valve closes to create c reate a vacuum in the inlet manifold.

When engine is stopped

Engine-ECU actuates the throttle valve control servo to fully close the throttle valve for 3 seconds. This cuts off the flow of intake air and prevents the engine from run on (dieseling).

When a problem develops

If the engine-ECU detects a serious s erious problem, it immediately closes the throttle valve fully to stop the engine. 21

Fuel System Sensor

Crank angle sensor

Cam position sensor

(56 teeth)

(5 teeth) 22

Fuel System Fuel filter

High cleaning efficiency filter

23

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, over,  has been located inside the fuel tank for f or fewer openings and hose bonding points 24

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 S. G.L end by MIL status as follow. Procedure for Small quantity learning

Precondition

Idling

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Vehic hicle spee speed d : 0k 0km/h m/h Acc ccele elerat rator or peda pedal: l: Fully Fully clos close e Powe Powerr ste steer erin ing g : not not ope opera rate ted d Elec lectric load : Off Water ater tem temp. p. : 80 deg deg.. or or high higher er AT oil oil temp temp.. : 60 deg. deg.or or high higher er Oil Oil tem tempe pera ratu ture re:: 30 30 deg deg.. or or hig highe herr Shift hift posi positi tio on: N or or P A/C : Off Idle Idle condi condition tion:: stabl stable e

When injector is changed or correction has to be applied to ECU for all cylinder before automatic learning mode

S.Q.L start

S.Q.L complete

MIL: Blink

MIL: Off

S.Q.L NG

After I/G Off to ON When injector is changed

25

Fuel System Common rail engine learning function After After fuel-related parts are replaced, the common rail engine must register their identification codes with the engine-ECU and execute learning. Registration and learning item

Operation type Injector replacement

Supply pump replacement

Engine-ECU replacement

1

Injector identification

Applicable

---

Applicable

2

Small injection quantity learning (SQL)

Applicable

---

Applicable

3

Supply pump correction learning

---

Applicable

---

Note : When the engine-ECU is replaced, collect in advance the injector identification code from the current engine-ECU. Doing it makes registration easy. 26

Fuel System 1. Common rail relative parts supply unit Supply unit

Components

caution

Common rail Ass’y

Fuel pressure sensor Fuel pressure limiter Common rail

Replace common rail ass’y when changing parts

Supply pump Ass’y

Suction control valve Fuel temperature sensor Supply pump

Replace supply pump ass’y when changing parts

Initialize learned value by MUT-III

Pay attention to the discharge because of injector drive voltage 85V

Register after erasing correction value by MUT-III

Injector ---------------------

Engine-ECU ----------------------

---------------------

After replacement

---------------------

Register the injector correction value, supply pump learned value by MUT-III 27

Fuel System 2. Caution and method of Injector correction(1/2) 1)

There are correctio correction n value, value, QR code code and and 15 bite of of hexadecim hexadecimal al numeral numeral (30 digits) which is written on the top surface of injector

Register the this hexadecimal numeral by using key board or touch panel of MUT-III to engine-ECU

28

Fuel System 2. Caution and method of Injector correction(2/2) 2) Make sure the replace r eplace 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 you replace ECU (engine warning lamp turn ON if there is no/partial value registered in ECU) ECU)

29

Fuel System 3. Diagnosis function Increase diagnosis items items (CDI: Approx.100 items , IDI:Approx.30items) IDI:Approx.30items) Ex) New diagnosis items Diagnosis items

Diagnosis code

Failure parts

Remarks

Abnormal of intake valve seized

P0638

ETV

Failure of ETV motor (judge of valve seized)

Abnormal of DC motor excessive current flow

P2118

ETV

Failure of ETV motor (excessive current)

Failure of NE/G phase unmatched

P0016

Crank angle sensor Cam position sensor

Cam position sensor and crank angle sensor output waveform unmatched

Injector function (non injection)

P0301 to P0304

ECU

Poor increasing angular speed by combustion

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 Purpose : Because individual injectors have different injection characteristics, the engine-ECU corrects injection time for each cylinder to improve i mprove injection accuracy. accuracy. For this reason, when the injector or engine-ECU is replaced, injector correction data must be registered afterwards in the engine-ECU using the MUT M UT-III. -III. Correction data is converted into an identification code consisting of 30 alphanumeric characters and printed on the injector connector.

31

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. 32

Fuel System Common rail engine learning function 1. Injector identification code registration procedure A. Injector ID code writing wr iting (Exchanging engine-ECU) engine-ECU) 1)

Befo Be fore re repl replac ace e the the curr curren entt eng engin inee-EC ECU, U, connect the MUT-III.

2)

Select “Special Function” from the function

menu of MUT-III. 3)

Select “INJ. ID Writing (Exchanging ECU)”

menu. 4)

Select “Injector ID Read & Save” menu.

Caution If the injector ID code is not registered, the engine warning lamp goes on and diagnosis code No. P1626 is logged. 33


A. Injector ID code writing w riting (Exchanging engine-ECU) engine-ECU) 5)

The injector ID code from the current engine -ECU is displayed.

6)

Click lick the the Chec eck k fro from tas task bar. ar.

7)

The injector ID code is saved to MUT-III from the current engine-ECU.

8)

Replace the new engine-ECU.

34


A. Injector ID code writing w riting (Exchanging engine-ECU) engine-ECU)

9)

Select “Saved Injector ID Writing” menu.

10)) 10

Sele Select ct the the injec injecto torr ID cod code e from from the cur curre rent nt engine-ECU, click the Check from task bar.

11)

The injecto injectorr ID code code from from the curren currentt engi engine ne -ECU is written to the new engine-ECU.

35

Fuel System Common rail engine learning function 1. Injector identification code registration procedure A. Injector ID code writing w riting (Exchanging engine-ECU) engine-ECU) 12)

For other way, select “All Injector ID Writing” menu.

13)) 13

Inpu Inputt the the eac each h inje injecti ction on ID cod code e by by keyboard.

14)) 14

Make Make sure sure that that the the engi engine ne war warni ning ng lamp lamp that that is on changes to blinking, indicating the registration is complete.

15)

Execut Execute e small small injectio injection n quanti quantity ty learnin learning. g.

Small Injection Quantity Learning Procedure

36


B. Injector ID code writing wr iting (Exchanging injector) 1)


menu of MUT-III. 2)

Select “INJ. ID Writing (Exchanging INJ)”

menu. 3)

Select number of replaced Injector ID writing menu or “All Injector ID Writing” menu.

4)

Input the each injection ID code by keyboard.

37

Fuel System Common rail engine learning function 2. Small Injection Quantity Learning procedure

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 injection quantity learning learning has not been executed, 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 or higher higher - Lamps, A/C condenser condenser fan and accessories : OFF - Transmission : Neutral - Power steering : Static state

1)

Put Put the the vehi vehicl cle e in the the left left-h -han and d idl idlin ing g sta stabl ble e condition.

2)


menu. 3)

Select “Learning” menu.

39

Fuel System Common rail engine learning function 2. Small injector quantity learning procedure 4)

Select “Small Injection qt. Learning” item.

5)

Click lick the the Chec eck k fro from tas task bar. ar.

Caution If the vehicle conditions go out of the learning l earning conditions during idling, learning is interrupted. i nterrupted. To re-execute learning, the ignition switch must Once be turned off.

6)

Cont Contin inue ue idli idling ng for for a abo bout ut 3 min minut utes es befo before re learning is completed.

7)

Conf Confir irm m tha thatt the the engi engine ne warn warnin ing g lamp lamp is off. If it still blinks, re-execute learning. 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 dri ve current and the rail pressure sensor output voltage. When the supply pump is replaced, therefore, this learning l earning must be executed. Re-learning is executed when the engine is idling after the learning l earning value in the engine-ECU Has been reset by the MUT-III. Suction Control Valve (SCV)

41

Fuel System Common rail engine learning function 3. Supply Pump Correction Learning procedure

- Accelerator pedal : OFF - Engine coolant temperature : 60ºC or higher - Fuel temperature : 30ºC or higher

1)

Select “Initialization” from the function

menu. 2)

Select item No. 21 “Supply pump exchange service”.

42

Fuel System Common rail engine learning function 3. Supply Pump Correction Learning procedure

3)

Click the Check.

4)

After fter initi initial aliz izin ing, g, run run the the engi engine ne at idle idle in the the left-hand conditions.

5)

Conf Confir irm m tha thatt the the item item No.6 No.65 5 Hig High h pre press ssur ure e pump learned status on MUT-III Service Data is “2”. “FF” : Initial Condition “0”

: Non-learning statue

“1”

: Temporary learning completed statue

“2”

: Learning Completed statue 43

Service Detail Initialization setting value for Supply pump. supply pump EEPROM discharge characteristic data

Initialization setting value

Replace

New data of Supply Pump

Setelah mengganti komponen harus dilakukan setting initialisasi initial isasi dengan kondisi IG switch OFF

44

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

Input new data ECU Replacement

Input QR

Setting

Input saved data

code

Saved data

Delete Code DTC P0201 Delete Code DTC P0604 Register Completed Register Completed

47

Small injection Quantity Learning Procedure PRASYARAT : - Engine coolant temperature : 80ºC atau lebih tinggi - AT temperature : 60ºC atau lebih tinggi - Lamps, A/C condenser fan and accessories : OFF

- Transmission : Neutral - Power steering : tidak dioperasikan 48

49

50

51

52

53

54

55

56

57

58

59

60

Injector ID Procedure Penggantian Injector

61

62

63

64

65

66

67

68

Injector ID Procedure Penggantian ECU

69

70

71

72

73

74

75

76

77

Supply Pump Initialization Procedure PRASYARAT : - Engine coolant temperature : 60ºC atau lebih tinggi - Fuel temperature : 30ºC atau lebih tinggi - Accelerator pedal : OFF

78

79

80

81

82

83

Service Detail Part-part yang tidak dapat digunakan lagi (Red Color) Injector

Injector Seal

O-Ring Cylinder head cover

Washer

Gasket

O-Ring

Fuel return pipe

Supply pump

84

Service Detail Mengganti Rail baru Mengganti pipa baru saat part-part berikut diganti

Part-part yang diganti

Mengganti pipa baru

*Injector

Discharge pipe

•

*Rail

*Supply pump

Discharge pipe

•

Inlet pipe

*Rail

•

Inlet pipe 85

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

3. Ganti pipa pengembalian dan start Engine (tidak bisa hidup)

) No leakage ( From return pipe ) 4. Gunakan MUT-III memeriksa kebocoran dengan actuator test

No leakage

Normal Fuel System

88

Service Detail Memeriksa getaran Engine Gunakan MUT-III untuk memeriksa getaran Engine

Active Test

Injector Injector Injector Injector

• • • •

Cut Cut Cut Cut

#1 #2 #3 #4

High voltage

Jangan melepas connector injector

89

Service Detail Penggantian Fuel Filter

Hand pump Fuel filter Warning switch

To supply pump

From Fuel tank

Fuel filter case (Aluminum)

Filter

Filter

Water level warning switch

90

Service Detail Fuel Filter Structure Hand pump

Fuel filter Warning switch

To Supply pump

From Fuel Tank

Filter

Fuel filter case (Aluminum)


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

Engine Speed sensor Fuel filter warning switch ECU

Combination

Fuel Filter warning

meter

lamp

To Supply pump Filter

Filter


93

Service Detail Fuel Filter Warning Lamp Status Fuel Filter / Water level warning lamp .

Warning Water level warning

Status

Step

1 Flashing

Fuel Filter warning

2 Showing 94

Service Detail Fuel Filter Warning Lamp Diagram Ketika Fuel filter warning lamp menyala, menyala, berarti perlu untuk mengganti mengganti filter dan reset warning lamp

Mengganti filter

Buka Fuel tank cap.

95

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 Memasang kembali Fuel filter

Install the fuel tank cap.

Install Inlet and Outlet hose.

97

Service Detail Fuel Filter Warning Lamp Diagram Install fuel filter / Reset warning lamp Reset warning lamp

Within 3

– 60 sec.

3 sec.

IG ON

OFF

Connect the connector

98

Service Detail Fuel Filter Warning Lamp Diagram Install fuel filter /Reset warning warning lamp

Keluarkan udara dari Fuel system. Hand pump

Finish

99

Fuel System

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