Hilux 2015 2018 manual 1gd ftv starting he thong khoi dong

Tài liệu hướng dẫn sửa chữa Hệ thống khởi động trên xe Hilux 2015 2018 manual 1gd ftv starting he thong khoi dong.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 STARTING ENGINE SWITCH(for RHD) COMPONENTS

ILLUSTRATION

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1GD-FTV STARTING ENGINE SWITCH(for RHD) INSPECTION

PROCEDURE

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

5 (SS1) - 6(AGND)

1 (SS2) - 6(AGND)

Not pushed 10 kΩ orhigher

5 (SS1) - 6(AGND)

1 (SS2) - 6(AGND)

Apply battery voltage between the terminals of the engine switch, and check the illumination condition of

the engine switch

Battery positive (+) →

Terminal 9 (SWIL) Battery negative (-) →

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1GD-FTV STARTING ENGINE SWITCH(for RHD) INSTALLATION

PROCEDURE

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

Attach the 2 claws to install the engine switch

a.

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1GD-FTV STARTING GLOW PLUG COMPONENTS

ILLUSTRATION

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1GD-FTV STARTING GLOW PLUG INSTALLATION

CAUTION / NOTICE / HINT

Replaced Parts (A) Pipes Requiring New Replacement

Common rail assembly

· ·· No 1 injection pipe sub-assemblyNo 2 injection pipe sub-assembly

Fuel inlet pipe sub-assembly

Measure the resistance of the glow plug when reinstalling it If the result is not as specified, replace theglow plug with a new one

Do not use any tools, such as air tools, which are liable to cause an impact to the glow plugs when

installing them

b.

Temporarily install the No 1 glow plug connector with the 4 nuts

a.

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

NOTICE:

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

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION

Tighten the 4 nuts

Torque:

2.2 N*m (22 kgf*cm, 19 in.*lbf) b.

Install the 4 glow plug screw grommets

c.

Using an E8 "TORX" socket wrench, install the stud bolt to the intake manifold

Torque:

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

4.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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1GD-FTV STARTING GLOW PLUG ON-VEHICLE INSPECTION

PROCEDURE

1.CHECK GLOW PLUG

Remove the glow plug connector

Click hereEngine / Hybrid System>1GD-FTV STARTING>GLOW PLUG>REMOVAL

Glow plugterminal -Body ground 20°C (68°F)

Approximately1.0 Ω

Be careful not to damage the glow plug assemblies, as this may cause an open circuit or shortenthe life of the glow plug assemblies

·

Do not allow oil or gasoline to contact the glow plug assembly when cleaning it

·Clean off any oil on the terminal with a dry cloth

·

Do not apply more than 11 V to the glow plug assembly, as this may cause an open circuit

·

Install the glow plug connector

Click hereEngine / Hybrid System>1GD-FTV STARTING>GLOW PLUG>INSTALLATION

c.

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1GD-FTV STARTING GLOW PLUG REMOVAL

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

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

while the engine is hot

·

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

the engine is hot

Replaced Parts (A) Pipes Requiring New Replacement

Common rail assembly

· ·· No 1 injection pipe sub-assemblyNo 2 injection pipe sub-assembly

Fuel inlet pipe sub-assembly

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CAUTION:

Make sure to wear protective gloves when performing work to avoid burns

CAUTION:

Make sure to wear protective gloves when performing work to avoid burns

Using an E8 "TORX" socket wrench, remove the stud bolt from the intake manifold

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Using a 10 mm deep socket wrench, remove the 4 glow plug assemblies

a.

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ILLUSTRATION

-*1 GLOW PLUG CONTROLLER *2 NO 1 GLOW PLUG CONTROLLER BRACKET

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ILLUSTRATION

-*1 GLOW PLUG CONTROLLER *2 NO 1 GLOW PLUG CONTROLLER BRACKET

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1GD-FTV STARTING GLOW PLUG CONTROLLER INSTALLATION

PROCEDURE

NOTICE:

1.INSTALL NO 2 GLOW PLUG CONTROLLER BRACKET 28559A

Install the No 2 glow plug controller bracket to the glow plug controller with the 2 screws

Torque:

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

2.INSTALL NO 1 GLOW PLUG CONTROLLER BRACKET 28559

Install the No 1 glow plug controller bracket to the glow plug controller with the 2 screws

Torque:

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

Connect the 4 connectors and attach the clamp

c.

4.CONNECT CABLE TO BATTERY TERMINAL

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1GD-FTV STARTING GLOW PLUG CONTROLLER REMOVAL

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:

1 PRECAUTION

2.DISCONNECT CABLE FROM BATTERY TERMINAL

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4.REMOVE NO 1 GLOW PLUG CONTROLLER BRACKET 28559

Remove the 2 screws and No 1 glow plug controller bracket from the glow plug controller

a.

Remove the 2 screws and No 2 glow plug controller bracket from the glow plug controller

a.

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1GD-FTV STARTING IGNITION SWITCH COMPONENTS

ILLUSTRATION

*1 IGNITION SWITCH ASSEMBLY *2 STEERING LOCK ACTUATOR OR UPPERBRACKET ASSEMBLY

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1GD-FTV STARTING IGNITION SWITCH INSPECTION

PROCEDURE

*a Component without harness connected (Ignition Switch Assembly)

Standard Resistance:

If the result is not as specified, replace the ignition switch assembly

a.

Tester Connection Condition Switch Condition Specified

7 (ACC) - 5

8 (IG1) - 5(AM1)

7 (ACC) - 5(AM1)

4 (AM2) - 3(IG2)

8 (IG1) - 5(AM1)

6 (ST1) - 5(AM1)

4 (AM2) - 3(IG2)

4 (AM2) - 2(ST2)

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1GD-FTV STARTING IGNITION SWITCH INSTALLATION

PROCEDURE

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION

Attach the 2 screws and install the ignition switch assembly

a.

Connect the connector

b.

2.INSTALL STEERING LOCK ACTUATOR OR UPPER BRACKET ASSEMBLY 45020B

3.INSTALL STEERING COLUMN ASSEMBLY

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1GD-FTV STARTING IGNITION SWITCH REMOVAL

PROCEDURE

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>DISASSEMBLY

1.REMOVE STEERING COLUMN ASSEMBLY

2.REMOVE STEERING LOCK ACTUATOR OR UPPER BRACKET ASSEMBLY 45020B

Detach the 2 screws and remove the ignition switch assembly

a.

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1GD-FTV STARTING PRE-HEATING SYSTEM ON-VEHICLE INSPECTION

NOTICE:

Turn the ignition switch off for 60 seconds before performing the following inspections

PROCEDURE

1.INSPECT ILLUMINATION DURATION OF GLOW INDICATOR LIGHT

Turn the ignition switch to ON and measure the length of time that the light remains illuminated

Light illumination duration:

Refer to the graph

HINT:

Depending on the engine coolant temperature, the indicator light illumination time changes as shown in

the illustration

a.

*a Glow Indicator Light Illumination Time

*b Engine Coolant Temperature

*c When atmospheric pressure is 100 kPa (1.0kgf/cm )2

2.INSPECT PRE-HEATING FUNCTION

Measure the voltage applied to the glow plug assemblies

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Standard Pre-heating Time:

Condition Pre-heating Time

Battery voltage at 14.5

Engine coolanttemperature 40°C

3.INSPECT AFTER GLOW

Measure the voltage applied to the glow plug assemblies after the engine is started

Engine coolanttemperature 20°C(68°F) to 41°C (106°F) 0 to 14 V

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1GD-FTV STARTING PRE-HEATING SYSTEM PARTS LOCATION

ILLUSTRATION

*5 GLOW PLUG CONTROLLER *6 INSTRUMENT PANEL JUNCTION BLOCKASSEMBLY

*7 RELAY BLOCK JUNCTION BLOCK - GLOW FUSE

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ILLUSTRATION

*5 GLOW PLUG CONTROLLER *6 INSTRUMENT PANEL JUNCTION BLOCKASSEMBLY

*7 RELAY BLOCK JUNCTION BLOCK - GLOW FUSE

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1GD-FTV STARTING PRE-HEATING SYSTEM SYSTEM DIAGRAM

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1GD-FTV STARTING RELAY ON-VEHICLE INSPECTION

PROCEDURE

1.INSPECT NO 1 STARTER RELAY ASSEMBLY (ST NO 1) 28300

If the result is not as specified, replace the No 1 starter relay assembly

a.

Tester Connection Condition Condition Specified

3 - 5

Battery voltagenot applied toterminals 1and 2

10 kΩ orhigherBattery voltage

applied toterminals 1and 2

Below 1 Ω

a.

Tester Connection Condition Condition Specified

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If the result is not as specified, replace the glow relay

3 - 5

Battery voltagenot applied toterminals 1and 2

10 kΩ orhigher

Battery voltageapplied toterminals 1and 2

Below 1 Ω

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1GD-FTV STARTING STARTER(for 2.2 kW Type) INSPECTION

PROCEDURE

CAUTION:

As a large electric current passes through the cable during this inspection, a thick cable must be used

Otherwise, the cable may become hot and cause injury

NOTICE:

These tests must be performed within 3 to 5 seconds to prevent the coil from burning out

Mount the starter assembly in a vise between aluminum plates

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When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-)lead from terminal C Check that the pinion gear remains out

If the clutch pinion gear returns inward, replace the magnet starter switch assembly

i.

*a Terminal CDisconnect

Inspect clutch pinion gear return

d.

i.

Disconnect

Return Inward

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Disconnect the negative (-) lead from the starter body Check that the clutch pinion gear returnsinward

If the clutch pinion gear does not return inward, replace the magnet starter switch assembly

Perform operation test without load

e.

Connect the lead wire to terminal C with the nut

Torque:

9.8 N*m (100 kgf*cm, 87 in.*lbf) i.

Connect the battery and an ammeter (AC/DC 400A probe) to the starter assembly as shown in theillustration

ii.

*a Starter Body

*b Terminal 50

*c Terminal 30

*d AC/DC 400A Probe

Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended Thenmeasure the current

Standard current:

120 A or less at 11 V

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

iii.

Tiêu đề	1gd-ftv Starting Engine Switch
Thể loại	manual
Năm xuất bản	2017
Thành phố	Australia

Định dạng
Số trang	57
Dung lượng	2,41 MB
File đính kèm	Hilux 2015-2018 Manual_He thong khoi dong.zip (2 MB)