Hilux 2015 2018 manual 1gd ftv engine control he thong dieu khien dong co

Tài liệu hướng dẫn sửa chữa Hệ thống điều khiển đông cơ trên xe Hilux 2015 2018 manual 1gd ftv engine control he thong dieu khien dong co . Cung cấp các thông tin cần thiết cho Kỹ thuật viên tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác

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1GD-FTV ENGINE CONTROL DIESEL THROTTLE BODY COMPONENTS

ILLUSTRATION

-*1 DIESEL THROTTLE BODY ASSEMBLY *2 NO 1 ENGINE COVER SUB-ASSEMBLY

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*9 NO 11 WATER BY-PASS HOSE *10 NO 14 WATER BY-PASS HOSE

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

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1GD-FTV ENGINE CONTROL DIESEL THROTTLE BODY INSTALLATION

PROCEDURE

Connect the connector to install the emission control valve wire to the diesel throttle body assembly

a.

Install a new gasket and the diesel throttle body assembly with the 2 bolts and 2 nuts

Torque:

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

Connect the connector and clamp

c.

for Cold Area Specification Vehicles:

Connect the No 11 water by-pass hose and No 14 water by-pass hose to the diesel throttle body

assembly, and slide the 2 clips to secure the hose

d.

Connect the fuel hose bracket with the bolt to the diesel throttle body assembly

Torque:

6.5 N*m (66 kgf*cm, 58 in.*lbf) e.

Install the intercooler air tube to the diesel throttle body assembly and tighten the hose clamp

Torque:

6.5 N*m (66 kgf*cm, 58 in.*lbf) a.

Connect the connector to the intake air temperature sensor

b.

Install the No 4 air hose to the intercooler air tube and tighten the 2 hose clamps

Torque:

6.5 N*m (66 kgf*cm, 58 in.*lbf) a.

Connect the oil return hose to the intercooler assembly and engine oil level dipstick guide, and slide the 2

clips to secure the hose

b.

Attach the 4 clamps

c.

Attach the 2 clips and install the No 1 engine cover sub-assembly to the No 2 water by-pass pipe

a.

Install the No 1 engine cover sub-assembly to the No 1 engine cover bracket and No 2 engine cover

bracket with the 2 nuts

Torque:

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

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Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>INITIALIZATION

w/ DPF:

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM(w/ DPF)>INITIALIZATION

5.PERFORM INITIALIZATION

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1GD-FTV ENGINE CONTROL DIESEL THROTTLE BODY ON-VEHICLE INSPECTION

PROCEDURE

Connect the GTS to the DLC3

Enter the following menus: Powertrain / Engine / Active Test / Diesel Throttle Target Angle / Data List /

Target Throttle Position and Actual Throttle Position

Powertrain > Engine > Active Test

Execute

d.

Active Test Display

Diesel Throttle Target Angle

Data List Display

Target Throttle PositionActual Throttle Position

Adjust "Diesel Throttle Target Angle" and check that "Actual Throttle Position" changes according to "TargetThrottle Position"

OK:

"Actual Throttle Position" changes according to "Target Throttle Position".

e.

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1GD-FTV ENGINE CONTROL DIESEL THROTTLE BODY REMOVAL

CAUTION / NOTICE / HINT

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

parts are removed, installed, or replaced during the diesel throttle body assembly removal/installation are shownbelow

Remove the 2 nuts from the No 1 engine cover bracket and No 2 engine cover bracket

a.

Detach the 2 clips and No 1 engine cover sub-assembly from the No 2 water by-pass pipe

NOTICE:

Make sure to lift the No 1 engine cover assembly upward, Pulling the No 1 engine cover

sub-assembly towards you may damage the No 1 engine cover sub-sub-assembly

b.

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Detach the 4 clamps

Disconnect the connector from the intake air temperature sensor

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Remove the bolt and disconnect the fuel hose bracket from the diesel throttle body assembly

a.

for Cold Area Specification Vehicles:

Slide the 2 clips and disconnect the No 11 water by-pass hose and No 14 water by-pass hose from the

diesel throttle body assembly

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Disconnect the connector to remove the emission control valve wire from the diesel throttle body assembly

e.

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1GD-FTV ENGINE CONTROL ECM COMPONENTS

ILLUSTRATION

*3 GLOVE COMPARTMENT DOOR ASSEMBLY *4 NO 1 ECM BRACKET

*5 NO 2 ECM BRACKET *6 NO 2 INSTRUMENT PANEL UNDER COVERSUB-ASSEMBLY

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ILLUSTRATION

*3 GLOVE COMPARTMENT DOOR ASSEMBLY *4 NO 1 ECM BRACKET

*5 NO 2 ECM BRACKET *6 NO 2 INSTRUMENT PANEL UNDER COVERSUB-ASSEMBLY

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1GD-FTV ENGINE CONTROL ECM INSTALLATION

PROCEDURE

Click hereDrivetrain>VF2CM TRANSFER / 4WD / AWD>4WD CONTROL ECU>INSTALLATION

Click hereVehicle Interior>INTERIOR PANELS / TRIM>LOWER INSTRUMENT PANEL>INSTALLATION

Install the No 2 ECM bracket with the 2 screws

Torque:

3.0 N*m (31 kgf*cm, 27 in.*lbf) a.

Install the No 1 ECM bracket with the 2 screws

Torque:

3.0 N*m (31 kgf*cm, 27 in.*lbf) a.

Connect the 2 4 wheel drive control ECU connectors and 6 ECM connectors

Connect the 6 ECM connectors

6.INSTALL NO 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Cover) 55607

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Click hereVehicle Interior>INTERIOR PANELS / TRIM>LOWER INSTRUMENT PANEL>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>REGISTRATION

w/ DPF:

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM(w/ DPF)>REGISTRATION

7.PERFORM REGISTRATION

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1GD-FTV ENGINE CONTROL ECM REMOVAL

CAUTION / NOTICE / HINT

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

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

PROCEDURE

Click hereVehicle Interior>INTERIOR PANELS / TRIM>LOWER INSTRUMENT PANEL>REMOVAL

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or

Procedure Necessary Procedures when not Performed Effects/Inoperative Link

Replacement of ECM

( ) w/ DPF:( )

for RC61:( ) for RC61F:( )

Code registration(Immobiliser system) Engine start function

See the Service Bulletinfor the registrationmethod

Learning valuessave

·Learning valueswrite

·VehicleIdentificationNumber (VIN)registration

·

Engine starting

·DTC P0630 isoutput

·

Performing iMTinstallationinformation reset

iMT system

·DTCs are output

·

1.REMOVE NO 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Cover) 55607

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Click hereDrivetrain>VF2CM TRANSFER / 4WD / AWD>4WD CONTROL ECU>REMOVAL

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Remove the 2 screws and No 1 ECM bracket

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Remove the 2 screws and No 2 ECM bracket

a.

*A for LHD

*B for RHD

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1GD-FTV ENGINE CONTROL ECD SYSTEM TERMINALS OF ECM

HINT:

Each ECM terminal's standard voltage is shown in the table below

In the table, first follow the information under "Condition" Look under "Terminal No (Symbol)" for the terminals

to be inspected The standard voltage between the terminals is shown under "Specified Condition"

Use the illustration above as a reference for the ECM terminals

Ignition switch ON 11 to 14 V

10 seconds elapsedafter ignition switch

G8511 (NSW)

Park/Neutral positionswitch assemblysignal

Ignition switch ON,shift lever not in P or

Ignition switch ON,shift lever in P or N Below 1.0 VIgnition switch ON,

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Clutch start switchsignal

clutch pedal fully

Ignition switch ON 4.5 to 5.5 V

G8630 (VCP2)

Power source ofaccelerator pedalposition sensor (forVPA2)

G8628 (VPA)

Accelerator pedalposition sensorsignal (for enginecontrol)

Ignition switch ON,accelerator pedalfully released 0.5 to 1.1 VAccelerator pedal

position sensorsignal (for enginecontrol)

Ignition switch ON,accelerator pedalfully depressed 3.0 to 4.6 V

G8631 (VPA2)

Accelerator pedalposition sensorsignal (for sensormalfunctiondetection)

Ignition switch ON,accelerator pedalfully released 0.9 to 2.3 V

Accelerator pedalposition sensorsignal (for sensormalfunctiondetection)

Ignition switch ON,accelerator pedalfully depressed 3.4 to 5.0 V

C5825 (VCVG)

Power source ofmass air flow metersub-assembly (forVG)

Idling, intake airtemperature at 20°C

C5835 (THIA)

Intake airtemperature sensor(turbo)

Idling, intake airtemperature at 0 to80°C (32 to 176°F) 0.5 to 3.4 VC57-34 (THW) -

C57-27 (ETHW) B - BR temperature sensorEngine coolant

Idling, enginecoolant temperature

at 80°C (176°F) 0.2 to 1.0 VG85-22 (STA) -

C576 (#1D+)

-C57-7 (#1D-) W - B assembly signalNo 1 Injector

Ignition switch ON 4.5 to 5.5 VC60-27 (G2+) -

C60-18 (G2-) R - W Camshaft positionsensor signal Idling (See waveform 3)Pulse generation

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C6020 (VCNE)

Power source ofcrankshaft positionsensor (specificvoltage)

C6028 (NE+)

-C60-19 (NE-) Y - R Crankshaft positionsensor signal Idling (See waveform 4)Pulse generation

G8613 (STP)

-C60-1 (E1) L - W-B Stop light switchassembly signal

Ignition switch ON,brake pedal

Ignition switch ON,brake pedal released 7.5 to 14 VG85-25 (TC) - C60-

G8510 (SPD)

Speed signal fromcombination meterassembly

Ignition switch ON,slowly wheel rotated (See waveform 5)Pulse generation

C5728 (VCPM)

Power source ofmanifold absolutepressure sensor(specific voltage)

atmospheric

Positive pressure of

170 kPa (1275mmHg, 50.2 in.Hg)applied

Pulse generation (See waveform 7)C58-2 (PRV+) -

C58-1 (PRV-) B - Y Pressure dischargevalve signal turned off after idlingIgnition switch Pulse generation

C591 (VNM+)

DC motor signal(turbocharger nozzlevane controlactuator)

C592 (VNM)

DC motor signal(turbocharger nozzlevane controlactuator)

Power source ofnozzle vane position

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C5929 (VCVL)

Power source ofthrottle position

C5921 (VLU)

-C59-20 (EVLU) W- L Throttle positionsensor signal

Ignition switch ON,throttle valve

Ignition switch ON,throttle valve fully closed 0.4 to 1.0 VC60-6 (M+) - C60-3

(ME01) G - W-B Diesel throttle dutysignal Engine warmed up,racing engine Pulse generation

Vacuum switchingvalve assembly (forEGR bypass valve)

on

0 to 1.5 V

Vacuum switchingvalve assembly (forEGR bypass valve)

Engine warmed up,idling (See waveform 8)Pulse generation

C60-1 (E1) W - W-B CAN communicationline Ignition switch ON (See waveform 9)Pulse generation

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*1: Manual Cooler System

*2: Automatic Air Conditioning System

Mass Air Flow Meter Sub-assembly Signal

ECM Terminal

Tester Range 1 V/DIV., 100 µsec./DIV

Condition Ignition switch ON

No 1 (to No 4) Injector Assembly Signal

ECM Terminal

Name

Between #1D+ and #1D- Between #2D+ and #2D- Between #3D+ and #3D-

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#4D-Condition Idling with warm engine

Camshaft Position Sensor Signal

ECM Terminal

G2-Tester Range 5 V/DIV., 20 msec./DIV

Condition Idling with warm engine

Crankshaft Position Sensor Signal

ECM Terminal

NE-Tester Range 2 V/DIV., 10 msec./DIV

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Tester Range 5 V/DIV., 10 msec./DIV

Condition Driving at vehicle speed of 40km/h (25 mph)

Engine Speed Signal

ECM Terminal

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PCV-Tester Range 10 V/DIV., 20 msec./DIV

Engine Speed Signal

ECM Terminal

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Condition Engine stopped, ignition switchON

CAN Communication Signal

ECM Terminal

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HINT:

The waveform varies depending on the LIN communication signal

LIN Communication Signal

ECM Terminal

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1GD-FTV ENGINE CONTROL ECD SYSTEM Turbocharger Noise

DESCRIPTION

HINT:

Turbocharger noise is classified into two types These are whistling sound and chattering sound During

troubleshooting, first determine the type of noise

Faults and Symptoms of Diesel Engine Components

Type of Abnormal Noise Outline of Abnormal Noise Major Trouble Area

Whistling sound (airflow sound)

The whistling sound volume andpitch are proportional to theturbocharger or engine speed Theabnormal noise level becomesclear when the engine speed isincreased

Chattering sound (metallic sound)

The chattering sound pitch is lowerthan the whistling sound pitch Has

a comparatively constant pitch that

is independent of the engine speedand vehicle speed

·Leak in intake system

·Damaged intake system

·

The turbochargervibrations are transmitted

to the exhaust pipe,causing noise andresonance

·

The turbochargervibrations are transmittedthrough the exhaust pipe

to the chassis (floor),causing noise andresonance in the chassis

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NEXT 2.PERFORM SIMULATION TEST

PROCEDURE

1.CONFIRM CONDITION IN WHICH NOISE OCCURRED

Result:

2.PERFORM SIMULATION TEST

Confirm with the customer the condition when noise occurred

HINT:

To clearly understand the conditions in which the noise occurred, the items in the table below are useful

a.

Accelerator pedal position During acceleration or deceleration?

Temperature

Road conditions

Noise level

Other symptomsNoise recognition What made the customer determine that thesound was a malfunction?

Ambient temperature

·Engine temperature (cold, warmed up,etc.)

·

City or highway driving

·Uphill or downhill

·

Did the noise occur suddenly, or buildgradually?

·Has the noise gradually been gettinglouder?

·

Lack of power

·High fuel consumption, etc

·

Proceed toNEXT

Check whether the noise described by the customer occurs

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A 3.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER B

8.CONFIRM NOISE SOURCE (FROM TURBOCHARGER SUB-ASSEMBLY OR NOT)

A 4.CHECK TURBOCHARGER SUB-ASSEMBLY B

5.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 5)

END (CAUSE CHECK EXCEPT THE TURBO CHARGER) A

3.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER

4.CHECK TURBOCHARGER SUB-ASSEMBLY

Result:

Check for the noise source with a sound scope

a.

The source of the noise is not the turbocharger, but a part other than the turbocharger (e.g a part inside

the engine, transmission, or vacuum pump)

b.

Sometimes gear noise may be mistaken for turbocharger noise For gear noise, pay attention to the gear

inside the engine and transmission gear

Check for damage to the compressor impeller

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REPLACE TURBOCHARGER SUB-ASSEMBLY

Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST MANIFOLD W/

TURBOCHARGER>REMOVAL

B

NEXT 6.REPLACE THE PARTS DETECTED IN PROCEDURE 5

NEXT 7.CONFIRM WHETHER THE NOISE PROBLEM HAS BEEN SUCCESSFULLY SOLVED

5.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 5)

For gear noise, pay attention to the gear inside the engine and transmission gear

·Rev the engine up and check if the noise reduces at the same time the engine speed decreases Ifthe noise reduces at the same time the engine speed decreases, it is gear noise If the noisereduces a short time after the engine speed decreases, it is turbocharger noise

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END NEXT

A 9.PERFORM SIMULATION TEST B

5.CHECK FOR NOISE FROM SOURCE OTHER THAN TURBOCHARGER (PROCEDURE 5) 8.CONFIRM NOISE SOURCE (FROM TURBOCHARGER SUB-ASSEMBLY OR NOT)

Connect the GTS to the DLC3

Enter the following menus: Powertrain / Engine and ECT / Active Test / Activate the VN Turbo Open

Powertrain > Engine and ECT > Active Test

Execute

d.

Tester Display

Activate the VN Turbo Open

Perform the Active Test under the conditions* from the time the noise occurred described by the customerand compare the noise to the noise heard when not performing the Active Test and check if the noise is

The noise is the same as in Procedure 2 (The noise does not change) B

By performing Activate the VN Turbo Open Active Test, the variable nozzle of the turbochargersub-assembly becomes fully open regardless of the engine condition, and the turbocharger speeddoes not increase

·

If the turbocharger sub-assembly is the cause of the noise, the noise will be reduced whenActivate the VN Turbo Open Active Test is performed because turbocharger speed does notincrease

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15.CHECK TURBOCHARGER SUB-ASSEMBLY C

21.CHECK TURBOCHARGER SUB-ASSEMBLY D

26.CHECK GEAR NOISE

Noise occurs (whistling or foghorn-like (airflow sound) during acceleration) C

Check that the turbine shaft rotates smoothly, without catching

TURBOCHARGER>INSPECTION

a.

Check for loose turbine mounting nuts and for axial play in the turbine shaft

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A 12.REPLACE TURBOCHARGER SUB-ASSEMBLY B

END NEXT

Replace the turbocharger sub-assembly

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*: Replace the turbocharger sub-assembly, as the abnormal noise may have been caused by interference

between the turbine blades and housing

Check for interference between the turbine wheel and the turbine housing

a.

Check that no soot or oil adheres to the turbocharger sub-assembly connectors

HINT:

If adhering soot or an oil leak exists, air leaking at that position may be the cause of the abnormal noise

a.

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REPLACE GASKET

18.CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY C

D

Soot adhering around the turbine housing, flange, or exhaust pipe clamp

Oil leak from the contact surface between the compressor housing and

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END NEXT

REPLACE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHICCONVERTER(w/o DPF)>REMOVAL

A 19.REPLACE EXHAUST PIPE CLAMP AND GASKET B

C

NEXT

18.CHECK EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

19.REPLACE EXHAUST PIPE CLAMP AND GASKET

Deformation or cracks on the exhaust manifold converter

Deformation or cracks on the turbine with valve housing sub-assembly

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END NEXT

Result:

Check that the abnormal noise has disappeared

a.

Proceed to

TURBOCHARGER>INSPECTION

a.

Check for loose turbine mounting nuts and for axial play in the turbine shaft

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END NEXT

Tiêu đề	1gd-ftv Engine Control Diesel Throttle Body
Trường học	Toyota Motor Corporation
Thể loại	service manual
Năm xuất bản	2017

Định dạng
Số trang	818
Dung lượng	13,38 MB
File đính kèm	Hilux 2015-2018 Manual_He thong dieu khien dong co.zip (11 MB)