Hilux 2015 2018 manual 1gd ftv emission control he thong kiem soat khi thai

Tài liệu hướng dẩn sửa chữa Hệ thống kiểm soát khí thải trên xe Hilux 2015 2018 manual 1gd ftv emission control he thong kiem soat khi thai . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác, hiệu quả

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR COMPONENTS

ILLUSTRATION

*1 DIFFERENTIAL PRESSURE SENSOR *2 NO 1 ENGINE COVER SUB-ASSEMBLY

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR INSTALLATION

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>INSTALLATION

Install the 2 air hoses to the differential pressure sensor, and slide the 2 clamps to secure the 2 hoses

Connect the connector to the differential pressure sensor

d.

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR ON-VEHICLE INSPECTION

PROCEDURE

Connect the GTS to the DLC3

Turn the ignition switch to ON

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Apply pressure to the differential pressure sensor assembly

Perform the inspection within the range of 0 to 98 kPa (0 to 1.0 kgf/cm , 0 to 14.2 psi)

If the result is not as specified, check the differential pressure sensor circuit

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1GD-FTV EMISSION CONTROL DIFFERENTIAL PRESSURE SENSOR REMOVAL

CAUTION / NOTICE / HINT

Disconnect the connector from the differential pressure sensor

a.

Remove the bolt and differential pressure sensor from the pipe clamp

b.

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Slide the 2 clamps and disconnect the 2 air hoses from the No 1 vacuum pipe and No 2 vacuum pipe

c.

Slide the 2 clamps and remove the 2 No 1 air hoses from the differential pressure sensor

d.

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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE COMPONENTS

ILLUSTRATION

*1 NO 1 ENGINE COVER SUB-ASSEMBLY *2 VACUUM CONTROL VALVE SET

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*1 NO 1 VACUUM SWITCHING VALVE ASSEMBLY *2 BRACKET

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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE INSPECTION

PROCEDURE

Measure the resistance according to the value(s) in the table below

1 - Bodyground

2 - Bodyground

20°C (68°F) 1 MΩ or higher

Check operation of the No 1 vacuum switching valve assembly

b.

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When a vacuum of 60 kPa (450 mmHg, 18 in.Hg) is applied to port F, check that air flows from port E tothe filter

Check that air flows from port E to port F

If the result is not as specified, replace the No 1 vacuum switching valve assembly

iii.

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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE INSTALLATION

PROCEDURE

Install the No 1 vacuum switching valve assembly to the bracket with the screw

Torque:

1.4 N*m (14 kgf*cm, 12 in.*lbf) a.

Connect the vacuum hose to the No 1 vacuum switching valve assembly

b.

Install the vacuum control valve set to the intake manifold with the 2 bolts

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Connect the 2 vacuum hoses to the No 2 vacuum transmitting pipe sub-assembly and No 2 EGR valve

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1GD-FTV EMISSION CONTROL EGR BYPASS VALVE SWITCHING VALVE REMOVAL

CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the

engine is hot

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>DIESEL THROTTLE BODY>REMOVAL

Remove the bolt and disconnect the engine wire bracket

a.

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Disconnect the 2 vacuum hoses from the No 2 vacuum transmitting pipe sub-assembly and No 2 EGR

valve assembly

b.

Remove the 2 bolts and vacuum control valve set from the intake manifold

c.

Disconnect the vacuum hose from the No 1 vacuum switching valve assembly

a.

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Remove the screw and No 1 vacuum switching valve assembly from the bracket

b.

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1GD-FTV EMISSION CONTROL EGR COOLER COMPONENTS

ILLUSTRATION

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*1 EGR VALVE BRACKET *2 NO 1 EGR COOLER AND NO 2 EGR VALVEASSEMBLY WITH ELECTRIC EGR CONTROL

VALVE ASSEMBLY

*5 NO 3 WATER BY-PASS PIPE SUB-ASSEMBLY *6 NO 4 WATER BY-PASS PIPE SUB-ASSEMBLY

-N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

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1GD-FTV EMISSION CONTROL EGR COOLER INSTALLATION

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR VALVE>INSTALLATION

Install a new gasket and the No 1 EGR cooler to the No 2 EGR valve assembly with electric EGR control

valve assembly with the 4 bolts

Torque:

25 N*m (255 kgf*cm, 18 ft.*lbf) a.

2.INSTALL NO 1 EGR COOLER AND NO 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

Temporarily install the No 1 EGR cooler and No 2 EGR valve assembly with electric EGR control valve

assembly to the intake manifold with the 4 bolts

Install the No 3 water by-pass pipe sub-assembly to the No 1 EGR cooler with the 2 bolts

a.

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Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR VALVE>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT

Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf)

Connect the No 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to

secure the hose

b.

Connect the No 8 water by-pass hose to the No 3 water by-pass pipe sub-assembly, and slide the clamp

to secure the hose

c.

Connect the No 4 fuel hose to the No 3 water by-pass pipe sub-assembly

d.

17.ADD ENGINE COOLANT

18.INSPECT FOR COOLANT LEAK

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1GD-FTV EMISSION CONTROL EGR COOLER REMOVAL

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after

parts are removed, installed, or replaced during the EGR cooler removal/installation are shown below

CAUTION:

engine is hot

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EGR VALVE>REMOVAL

Necessary Procedure After Parts Removed/Installed/Replaced

EGR control valve

1.DRAIN ENGINE COOLANT

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CAUTION:

engine is hot

12.DISCONNECT NO 3 WATER BY-PASS PIPE SUB-ASSEMBLY 16206B

Disconnect the No 4 fuel hose from the No 3 water by-pass pipe sub-assembly

a.

Slide the clamp and disconnect the No 8 water by-pass hose from the No 3 water by-pass pipe

sub-assembly

b.

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13.DISCONNECT NO 4 WATER BY-PASS PIPE SUB-ASSEMBLY 16209

16.REMOVE NO 1 EGR COOLER AND NO 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR

CONTROL VALVE ASSEMBLY

Remove the 4 bolts and No 1 EGR cooler and No 2 EGR valve assembly with electric EGR control valve

assembly from the intake manifold

a.

Remove the 4 bolts and No 1 EGR cooler from the No 2 EGR valve assembly with electric EGR control

valve assembly

a.

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Remove the gasket

b.

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1GD-FTV EMISSION CONTROL EGR VALVE INSPECTION

PROCEDURE

1.VISUALLY CHECK ELECTRIC EGR CONTROL VALVE ASSEMBLY 25800

Visually check the electric EGR control valve assembly for deposits

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NOTICE:

If light passes through (there is a gap between the valve and body), replace the electric EGR control valveassembly

Do not forcibly open the valve as it may be damaged or deformed

Check that the valve does not have heavy carbon deposits and is not stuck

If necessary, replace the No 2 EGR valve assembly

c.

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1GD-FTV EMISSION CONTROL EGR VALVE INSTALLATION

PROCEDURE

Using an E8 "TORX" socket wrench, install the 4 stud bolts to the No 2 EGR valve assembly

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Install a new gasket and the No 2 EGR valve assembly to the No 1 EGR cooler with the 4 bolts

Torque:

25 N*m (255 kgf*cm, 18 ft.*lbf) b.

Install a new gasket and the EGR valve adapter to the No 2 EGR valve assembly with the 2 bolts

Torque:

25 N*m (255 kgf*cm, 18 ft.*lbf) a.

3.INSTALL NO 1 EGR COOLER AND NO 2 EGR VALVE ASSEMBLY

Temporarily install the No 1 EGR cooler and No 2 EGR valve assembly to the intake manifold with the 4

Install the vacuum control valve set to the intake manifold with the 2 bolts

Torque:

a.

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Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Install 2 new gaskets and the No 1 EGR pipe sub-assembly to the exhaust manifold and EGR valve adapterwith 4 new nuts

Torque:

29 N*m (296 kgf*cm, 21 ft.*lbf) b.

Connect the No 1 EGR pipe sub-assembly to the vacuum transmitting pipe sub-assembly with the bolt

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) c.

Connect the No 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Connect the water hose to the No 2 EGR valve assembly, and slide the clamp to secure the hose

b.

Connect the No 7 water by-pass hose to the No 1 EGR cooler, and slide the clamp to secure the hose

c.

Install the No 3 water by-pass pipe sub-assembly to the No 1 EGR cooler with the 2 bolts

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Connect the No 8 water by-pass hose to the No 3 water by-pass pipe sub-assembly, and slide the clamp

to secure the hose

b.

Connect the No 4 fuel hose to the No 3 water by-pass pipe sub-assembly

c.

Install a new gasket and the electric EGR control valve assembly to the No 2 EGR valve assembly with the

2 bolts

Torque:

a.

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25 N*m (255 kgf*cm, 18 ft.*lbf)

Connect the No 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to

secure the hose

b.

Attach the clamp and connect the connector to the common rail assembly

c.

Install 2 new gaskets and No 2 EGR pipe to the electric EGR control valve assembly and the intake

manifold with the 4 nuts

Torque:

29 N*m (296 kgf*cm, 21 ft.*lbf) a.

Install the EGR valve bracket to the electric EGR control valve assembly and intake manifold with the bolt

and nut

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf) a.

Connect the connector to the vacuum control valve set

a.

Attach the clamp and install the bolt

Torque:

18.5 N*m (189 kgf*cm, 14 ft.*lbf) b.

Attach the clamp and connect the connector to the power steering oil pressure switch

Connect the connector to the sensor wire of the common rail assembly

ii.

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Connect the connector to the glow plug connector

Connect the fuel filter assembly to the fuel filter support

a.

Attach the clamp and slide the lead wire as shown in the illustration to install it

b.

Install the No 2 engine cover bracket to the No 3 water by-pass pipe sub-assembly and No 2 EGR valve

assembly with the 2 bolts

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Install the No 2 hose to hose tube to the cylinder head cover sub-assembly and hose bracket with the 2

bolts

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Connect the union to check valve hose to the vacuum pump assembly, and slide the clamp to secure the

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Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLING SYSTEM>ON-VEHICLE INSPECTION

Install the turbo pressure sensor to the No 3 water by-pass pipe sub-assembly with the bolt

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Connect the connector to the turbo pressure sensor

b.

Install the gas filter to the gas filter bracket

a.

Connect the 2 vacuum hoses to the turbo pressure sensor and intake manifold

b.

Install the No 2 water by-pass pipe to the cylinder head cover sub-assembly, No 3 water by-pass pipe

sub-assembly and No 2 engine cover bracket with the 4 bolts

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Connect the No 16 water by-pass hose to the No 1 EGR cooler, and slide the clamp to secure the hose

w/o Viscous Heater:

Connect the No 2 water by-pass pipe to the No 13 water by-pass hose, and slide the clamp to secure thehose

19.ADD ENGINE COOLANT

20.INSPECT FOR COOLANT LEAK

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1GD-FTV EMISSION CONTROL EGR VALVE ON-VEHICLE INSPECTION

CAUTION:

To prevent injury due to contact with an operating fan and generator V belt or cooling fan, keep your hands andclothing away from the fan and generator V belt and cooling fans when working in the engine compartment withthe engine running

PROCEDURE

With the engine stopped, check that the EGR cooler by-pass valve regulating link is in the bypass position

as shown in the illustration

When the engine coolant temperature is 80°C (176°F) or more, racing the engine at 1500 rpm or more,

check that the EGR cooler by-pass valve regulating link is in the cooler position The EGR cooler by-pass

valve regulating link returns to the bypass position when idling

d.

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1GD-FTV EMISSION CONTROL EGR VALVE REMOVAL

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after

parts are removed, installed, or replaced during the EGR valve removal/installation are shown below

CAUTION:

engine is hot

PROCEDURE

EGR control valve

1.DRAIN ENGINE COOLANT

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w/ Viscous Heater:

Slide the clamp and disconnect the No 2 water by-pass pipe from the water hose sub-assembly

a.

*1 Water Hose Sub-assembly

*2 No 13 Water By-pass Hose

*4 Heater Hose

w/o Viscous Heater:

Slide the clamp and disconnect the No 2 water by-pass pipe from the No 13 water by-pass hose

Disconnect the 2 vacuum hoses from the turbo pressure sensor and intake manifold

a.

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Remove the gas filter from the gas filter bracket

b.

Disconnect the connector from the turbo pressure sensor

a.

Remove the bolt and turbo pressure sensor from the No 3 water by-pass pipe sub-assembly

b.

Slide the clamp to disconnect the union to connector tube hose from the No 1 hose to hose tube

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Remove the 2 bolts and No 2 engine cover bracket from the No 3 water by-pass pipe sub-assembly and

No 2 EGR valve assembly

a.

Disconnect the clamp and slide the lead wire as shown in the illustration to remove it

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Detach the 2 clamps and disconnect the 2 connectors from the turbocharger sub-assembly

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Remove the bolt, nut and EGR valve bracket from the electric EGR control valve assembly and intake

manifold

a.

Remove the bolt, 4 nuts and No 2 EGR pipe from the electric EGR control valve assembly and intake

Tiêu đề	1gd-ftv Emission Control
Trường học	Toyota Motor Corporation
Chuyên ngành	Emission Control
Thể loại	manual
Năm xuất bản	2012
Thành phố	Toyota City

Định dạng
Số trang	102
Dung lượng	5,56 MB
File đính kèm	Hilux 2015-2018 Manual_He thong kiem soat khi thai.zip (5 MB)