Hilux 2015 2018 manual 1gd ftv fuel he thong nhien lieu

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1GD-FTV FUEL COMMON RAIL COMPONENTS

ILLUSTRATION

-*1 COMMON RAIL ASSEMBLY *2 FUEL INLET PIPE SUB-ASSEMBLY

*3 NO 1 INJECTION PIPE SUB-ASSEMBLY *4 NO 2 INJECTION PIPE SUB-ASSEMBLY

*5 NO 4 FUEL HOSE *6 NO 4 FUEL PIPE SUB-ASSEMBLY

*7 WIRING HARNESS CLAMP BRACKET *8 WIRE HARNESS

*9 NO 1 INJECTION PIPE CLAMP *10 NO 2 INJECTION PIPE CLAMP

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Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping": N*m (kgf*cm,ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

* For use with SST or union nut wrench ● Non-reusable part

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1GD-FTV FUEL COMMON RAIL INSPECTION

PROCEDURE

Inspect the fuel pressure sensor

a.

*a Component without harness connected (Fuel Pressure Sensor)

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

Standard Resistance:

If the result is not as specified, replace the common rail assembly

i.

Tester Connection Condition Condition Specified

5 (PR) - 4 (E2)

25°C (77°F)

16.4 kΩ orless

The temperature indicated in "Condition" is the temperature of the pressure discharge valve

If the result is not as specified, replace the common rail assembly

i.

1 - 2 20°C (68°F) 0.42 to 0.52 Ω

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1GD-FTV FUEL COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>INSTALLATION

When replacing the parts in the following chart (A), replace the No 1 injection pipe sub-assembly, No 2injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones

·

Replaced Parts (A) Pipes Requiring New Replacement

Injector assembly (including shuffling theinjector assemblies between the

cylinders)

·Common rail assembly

·Cylinder head sub-assembly

·Cylinder block sub-assembly

·Cylinder head gasket

·Timing chain case assembly

Install the common rail assembly with the 2 nuts

Torque:

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

Connect the fuel pressure sensor connector to the common rail assembly

b.

Attach the wire harness clamp

c.

Connect the No 4 fuel hose to the common rail assembly, and slide the clamp to secure it

a.

3.TEMPORARILY INSTALL NO 1 AND NO 2 INJECTION PIPE SUB-ASSEMBLY

4.TIGHTEN NO 1 AND NO 2 INJECTION PIPE SUB-ASSEMBLY

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

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

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION

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

7.INSTALL WIRING HARNESS CLAMP BRACKET

8.INSTALL EGR COOLER SUB-ASSEMBLY AND NO 2 EGR VALVE ASSEMBLY WITH

ELECTRIC EGR CONTROL VALVE ASSEMBLY

25800

9.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

10.BLEED AIR FROM FUEL SYSTEM

11.INSPECT FOR FUEL LEAK

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1GD-FTV FUEL COMMON RAIL REMOVAL

NOTICE:

PROCEDURE

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the

battery terminal Therefore, make sure to read the disconnecting the cable from the battery terminal notice

before proceeding with work

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

NOTICE:

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

Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL

·

cylinders)

2.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3.REMOVE EGR COOLER SUB-ASSEMBLY AND NO 2 EGR VALVE ASSEMBLY WITH

25800

4.REMOVE WIRING HARNESS CLAMP BRACKET

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Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>REMOVAL

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

5.REMOVE NO 1 AND NO 2 INJECTION PIPE SUB-ASSEMBLY

Slide the clamp and disconnect the No 4 fuel hose from the common rail assembly

a.

Detach the wire harness clamp

a.

Disconnect the fuel pressure sensor connector from the common rail assembly

b.

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Remove the 2 nuts and common rail assembly

NOTICE:

Do not remove the pressure discharge valve or fuel pressure sensor

c.

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1GD-FTV FUEL FUEL FILTER COMPONENTS

ILLUSTRATION

*1 FUEL FILTER ELEMENT ASSEMBLY *2 FUEL FILTER CAP

*3 CLOGGING SWITCH CONNECTOR *4 O-RING

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1GD-FTV FUEL FUEL FILTER INSPECTION

PROCEDURE

Inspect the level warning switch

a.

*a Component without harness connected (Level Warning Switch)

*b Level Warning Switch Connector

If the result is not as specified, replace the fuel filter assembly

i.

3 - 4

Float at upperend position Below 1 ΩFloat at lower

end position 10 kΩ orhigher

Inspect the clogging switch

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If the result is not as specified, replace the fuel filter assembly

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1GD-FTV FUEL FUEL FILTER REPLACEMENT

Detach the clamp and disconnect the No 1 fuel hose from the No 2 fuel pipe clamp

a.

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

b.

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Disconnect the level warning switch connector

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Disconnect the clogging switch connector

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To remove the fuel filter cap, pull up one side of the fuel filter cap, and then lift it off

Remove the fuel filter element assembly from the fuel filter case

m.

Remove the O-ring from the fuel filter case

n.

Clean the fuel filter case and remove dirt completely

a.

Install a new O-ring to the fuel filter case

b.

*1 O-ring

*2 Fuel Filter Element Assembly

Install the fuel filter element assembly to the fuel filter case

c.

Align the mark on the fuel filter cap and the mark on the fuel filter case

d.

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Push the fuel filter cap onto the fuel filter case by hand

Standard clearance (A):

1.5 mm (0.0590 in.) or less

HINT:

The clearance between the fuel filter cap and fuel filter case should be even around the entire

circumference of the fuel filter cap and fuel filter case

e.

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Turn the fastener nut until a "click" sound is heard

HINT:

Just before the marks of the fuel filter case and nut align, the fastener nut will become more difficult to

turn Use a screwdriver as a lever to turn the fastener nut

f.

Measure the distance between the marks on the fuel filter cap and fuel filter case, and the clearance

between the fuel filter cap and fuel filter case

Standard distance (A):

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

*1 No 1 Fuel Hose

*2 No 2 Fuel Pipe Clamp

*a Paint Mark

3.RESET FUEL SYSTEM WARNING LIGHT

Turn the ignition switch to ON

a.

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After turning the ignition switch to ON, connect the level warning switch connector no sooner than 3

seconds have passed but no later than 60 seconds have passed

b.

Check that the combination meter's fuel system warning light turns off

c.

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1GD-FTV FUEL FUEL FILTER(for Cylinder Block Side) COMPONENTS

ILLUSTRATION

*1 FUEL FILTER CAP WITH ELEMENT *2 ENGINE WIRE

*3 NO 4 FUEL PIPE SUB-ASSEMBLY *4 UNION BOLT

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

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1GD-FTV FUEL FUEL FILTER(for Cylinder Block Side) REPLACEMENT

2.REMOVE FUEL FILTER CAP WITH ELEMENT

Disconnect the crankshaft position sensor connector and remove the 2 bolts

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Remove the 2 fuel pipe clamps from the No 3 fuel pipe and fuel filter assembly

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Remove the 2 nuts and disconnect the fuel filter assembly from the cylinder block sub-assembly

Remove the 4 screws and fuel filter element from the fuel filter assembly

3.INSTALL FUEL FILTER CAP WITH ELEMENT

Clean the fuel filter assembly and remove dirt completely

Connect the fuel filter assembly to the cylinder block sub-assembly with the 2 nuts

Torque:

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

Install the No 3 fuel pipe and a new gasket to the fuel filter assembly with the union bolt

Torque:

42 N*m (428 kgf*cm, 31 ft.*lbf) f.

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Install the 2 fuel pipe clamps to the fuel filter assembly and No 3 fuel pipe

Connect the crankshaft position sensor connector

i.

Attach the 3 clamps and connect the engine wire with the 2 bolts

Torque:

j.

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for bolt A : 12.5 N*m (127 kgf*cm, 9 ft.*lbf) for bolt B : 18.5 N*m (189 kgf*cm, 14 ft.*lbf)

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1GD-FTV FUEL FUEL INJECTOR COMPONENTS

ILLUSTRATION

-*1 HARNESS BRACKET *2 INJECTOR ASSEMBLY

*3 NO 1 INJECTION PIPE SUB-ASSEMBLY *4 NO 2 INJECTION PIPE SUB-ASSEMBLY

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*5 NO 1 FUEL PIPE *6 NOZZLE HOLDER GASKET

*7 NOZZLE LEAKAGE PIPE ASSEMBLY *8 WIRING HARNESS CLAMP BRACKET

*9 NO 5 FUEL HOSE *10 INJECTION NOZZLE SEAT

*11 NOZZLE HOLDER CLAMP *12 WASHER

*13 NOZZLE HOLDER CLAMP BOLT *14 UNION BOLT

Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping": N*m (kgf*cm,ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

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1GD-FTV FUEL FUEL INJECTOR INSPECTION

PROCEDURE

Inspect the injector assembly

a.

HINT:

The temperature indicated in "Condition" is the temperature of the injector assembly

If the result is not as specified, replace the injector assembly

i.

1 - 2 20°C (68°F) 0.52 to 0.66 Ω

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1GD-FTV FUEL FUEL INJECTOR INSTALLATION

cylinders)

Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly

a.

Install 4 new injection nozzle seats to the cylinder head sub-assembly

a.

Apply a light coat of engine oil to the O-ring on each injector assembly

b.

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Install a new O-ring to each injector assembly

3.TEMPORARILY INSTALL NO 1 AND NO 2 INJECTION PIPE SUB-ASSEMBLY

Temporarily install the 2 No 2 injection pipe sub-assemblies 4 union nuts

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Tighten the 4 nozzle holder clamp bolts

Torque:

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

5.TIGHTEN NO 1 AND NO 2 INJECTION PIPE SUB-ASSEMBLY

Using SST, tighten the No 1 and No 2 injection pipe sub-assemblies 8 union nuts

SST

09245-11010 Torque:

Specified tightening torque : 40 N*m (408 kgf*cm, 30 ft.*lbf) HINT:

a.

*a Torque Wrench Fulcrum Length

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench

·When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180

mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)

·

Temporarily install the nozzle leakage pipe assembly and 4 new gaskets with the 4 union bolts and bolt

a.

Tighten the 4 union bolts and bolt in the order shown in the illustration

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf) b.

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Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EXHAUST FUEL ADDITION

INJECTOR>INSTALLATION

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

NOTICE:

Connect the No 5 fuel hose to the nozzle leakage pipe assembly

c.

7.INSTALL HARNESS BRACKET

Install the harness bracket with the bolt

Torque:

8.4 N*m (86 kgf*cm, 74 in.*lbf) a.

8.INSTALL WIRING HARNESS CLAMP BRACKET

Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly

Torque:

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

Connect the pressure discharge valve connector to the common rail assembly

b.

10.INSTALL EGR COOLER SUB-ASSEMBLY AND NO 2 EGR VALVE ASSEMBLY WITH

25800

11.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

12.PERFORM REGISTRATION

Perform registration of injector compensation codes

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

a.

Perform registration of pilot quantity learning

b.

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1GD-FTV FUEL FUEL INJECTOR ON-VEHICLE INSPECTION

PROCEDURE

HINT:

If the injector compensation code is not correctly registered, it may cause malfunctions

Start the engine and drive the vehicle until the engine coolant temperature reaches 60°C (140°F) or higher

Read the values when the engine is idling

Injector Feedback Val #1 Injector Feedback Val #2 Injector Feedback Val #3 Injector Feedback Val #4

3

2.CHECK INJECTOR COMPENSATION CODE

Read the injector compensation code

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1GD-FTV FUEL FUEL INJECTOR REMOVAL

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

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

NOTICE:

PROCEDURE

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the

battery terminal Therefore, make sure to read the disconnecting the cable from the battery terminal notice

before proceeding with work

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

NOTICE:

Necessary Procedure After Parts Removed/Installed/Replaced

·

Pilot quantitylearning

·

cylinders)

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

Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL INJECTOR>ON-VEHICLE INSPECTION

Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>EXHAUST FUEL ADDITION

INJECTOR>REMOVAL

3.REMOVE EGR COOLER SUB-ASSEMBLY AND NO 2 EGR VALVE ASSEMBLY WITH

25800

4.CHECK INJECTOR COMPENSATION CODE

6.REMOVE WIRING HARNESS CLAMP BRACKET

Disconnect the pressure discharge valve connector from the common rail assembly

a.

Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly

b.

7.REMOVE HARNESS BRACKET

Remove the bolt and harness bracket

a.

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NOTICE:

After removing the No 1 and No 2 injection pipe sub-assemblies, cover the common rail assembly with

electrical tape to prevent dirt or foreign objects from entering the pipe inlet Also, protect the injector inlets withelectrical tape or plastic bags

Slide the clamp and disconnect the No 5 fuel hose from the nozzle leakage pipe assembly

9.REMOVE NO 1 AND NO 2 INJECTION PIPE SUB-ASSEMBLY

Using SST, loosen the No 1 and No 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector

assembly side and common rail assembly side

SST

09245-11010 a.

b.

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Remove the 2 No 1 injection pipe sub-assemblies and 2 No 2 injection pipe sub-assemblies

NOTICE:

When removing the No 1 injection pipe sub-assembly and No 2 injection pipe sub-assembly, store the

injector assemblies in the correct order so that they can be returned to their original locations when

reassembling

Remove the 4 nozzle holder clamp bolts, 4 washers and 4 nozzle holder clamps

a.

Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly

NOTICE:

When removing the injector assembly, store the injector assemblies in the correct order so that they can

be returned to their original locations when reassembling

b.

Remove the O-ring from each injector assembly

c.

Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly

a.

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1GD-FTV FUEL FUEL SENDER GAUGE ASSEMBLY INSPECTION

PROCEDURE

Check the fuel sender gauge assembly output voltage

*a Component without harness connected (Fuel Sender Gauge Assembly)

*b Voltage applied between terminals

Be careful when connecting the leads, as the fuel sender gauge assembly may be damaged ifthe leads are connected to the wrong terminals

·

Do not apply more than 6 V to terminals 1 (FV) and 2 (FE)

·

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

*: The output voltage changes depending on the voltage applied to the terminals

Output voltage (F) = (0.850 x Voltage applied to terminals) to (0.922 x Voltage applied toterminals)

·Output voltage (E) = (0.068 x Voltage applied to terminals) to (0.140 x Voltage applied toterminals)

·

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1GD-FTV FUEL FUEL SENDER GAUGE ASSEMBLY INSTALLATION

PROCEDURE

Click hereEngine / Hybrid System>1GD-FTV FUEL>FUEL TANK>INSTALLATION

Set the fuel sender gauge assembly on the fuel tank vent tube assembly Then slide the fuel sender gaugedownward to install it

Tiêu đề	Hilux 2015 2018 Manual 1GD FTV Fuel System
Trường học	Toyota Motor Corporation
Chuyên ngành	Fuel System
Thể loại	service manual
Năm xuất bản	2012
Thành phố	Toyota City

Định dạng
Số trang	102
Dung lượng	4,42 MB
File đính kèm	Hilux 2015-2018 Manual_He thong nhien lieu.zip (4 MB)