Beruflich Dokumente
Kultur Dokumente
00400706EA
Revision History
Date 2009.10 Visual contents addition Visual contents are video and animation used for manual explanation. Visual contents can be viewed by clicking the appropriate button. Items added to the visual contents The following items have been added to Microinjection Quantity Learning Control under FUEL INJECTION CONTROL". Determinations for learning conditions Single microinjection operation Detecting the change in rotational speed via injection Correcting the injection pulse width (TQ), and actual injection quantity (Q) characteristics Revision Contents
2009 DENSO CORPORATION All rights reserved. This material may not be reproduced or copied, in whole or in part, without the written permission of DENSO Corporation.
Table of Contents
Table of Contents
Operation Section
1. PRODUCT APPLICATION INFORMATION
1.1 1.2 1.3 1.4 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Applicable Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2. SUPPLY PUMP
2.1 2.2 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3. RAIL
3.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
4. INJECTOR
4.1 4.2 Change Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Quick Response (QR) Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
7. ENGINE ECU
7.1 7.2 7.3 LAND CRUISER PRADO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 DYNA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 IMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1 1
Operation Section
Operation Section
1 2
Part Name Crankshaft Position Sensor Camshaft Position Sensor Accelerator Pedal Module Manifold Absolute Pressure (MAP) Sensor Coolant Temperature Sensor Intake Air Temperature Sensor Exhaust Recirculation Valve DYNA Part Name Supply Pump Injector Gas (EGR)
Remarks
101397-123#
25800-30190
Manufacturer Part Number 22100-30090 23670-30380 23670-30390 23810-30100 89661-25290 89661-25300 89870-25030 89870-25040 90919-05066 90919-05052 89281-35020 89421-20200 89422-33030 89727-60010
Remarks SCV: 294200-004# Different connector, for use with cylinders 1 and 2
Rail
095440-095# 275900-053#
MT, 2WD, Europe, Euro 4 (C/D), with charging regulation when starting MT, 2WD, Europe, Euro 4 (C/D), without charging regulation when starting
Engine ECU 275900-054# EDU Crankshaft Position Sensor Camshaft Position Sensor Accelerator Pedal Module MAP Sensor Coolant Temperature Sensor Intake Air Temperature Sensor 101310-570# 101310-581# 029600-143# 029600-116# 198300-302# 079800-780# 179700-045# 071500-237#
1 3
Operation Section
Part Name Throttle Position Sensor EGR Valve IMV Part Name
Remarks
Manufacturer Part Number 22100-30120 22100-30090 22100-0L060 22100-0L070 23670-30400 23670-30410 23670-0L090 23670-0L100 23810-30100 23810-0L030 89661-0KN00 89661-0KN20 89661-0KN30 89661-0KN40 89661-0KN60 89661-0KN80 89661-0KP00 89661-0KP20 89661-0KP40 89661-0KP50 89661-0KN10 89661-0KN50 89661-0KN90 89661-0KP10 89661-0KP30 89661-0KN70 89661-0KP60 89870-71070 89870-71080
Remarks 1KD, Europe, low lubrication 1KD/2KD, Thailand 1KD, Europe, Australia, Thailand 1KD/2KD, Europe, Thailand, India, low lubrication 1KD/2KD 2KD 1KD/2KD 2KD 1KD/2KD 1KD/2KD 1KD, MT, PT-4WD, Europe, Euro 4 1KD, MT, 2WD, Australia, Euro 4 1KD, MT, PT-4WD, Australia, Euro 4 1KD, AT, PT-4WD, Europe, Euro 4 1KD, AT, PT-4WD PRE, Australia, Euro 4 2KD, MT, 2WD, Europe, Euro 4 Class 2 2KD, MT, 2WD, Europe, Euro 4 Class 3 2KD, MT, PT-4WD, Europe, Euro 4 2KD, MT, 2WD PRE, Thailand, Euro 3 2KD, MT, PT-4WD, Thailand, Euro 3 1KD, MT, PT-4WD, Europe, Euro 4 1KD, AT, PT-4WD, Europe, Euro 4 2KD, MT, 2WD, Europe, Euro 4 Class 2 2KD, MT, 2WD, Europe, Euro 4 Class 3 2KD, MT, PT-4WD, Europe, Euro 4 1KD, MT, FT-4WD, India, Euro 4(W/O OBD) 2KD, MT, 2WD, India, Euro 4 (W/O OBD)
Supply Pump
Injector
295050-021# SM295050-018# SM295050-019# 095440-095# SM095440-095# MA275900-055# MA275900-056# MA275900-057# MA275900-058# MA275900-059# MA275900-060# MA275900-061# MA275900-062# MA275900-063# MA275900-064# RB275900-065# RB275900-066# RB275900-067# RB275900-068# RB275900-069# HA275900-070# HA275900-071#
Rail
Engine ECU
Engine ECU
EDU
101310-590# 101310-591#
Operation Section
1 4
Part Name Crankshaft Position Sensor Camshaft Position Sensor MAP Sensor Coolant Temperature Sensor Intake Air Temperature Sensor EGR Valve
DENSO Part Number 029600-063# 029600-115# 079800-913# 179700-045# 170400-602# 101397-113# 101397-114# 101397-116#
Manufacturer Part Number 90919-05025 90919-05050 89421-20200 89421-71030 89424-12010 25800-30100 25800-30110 25800-30120
Remarks
1 5
Operation Section
EGR Cooler
Supply Pump
Fuel Filter
Fuel Cooler
Fuel Tank
Q004457E
Operation Section
1 6
2. SUPPLY PUMP
2.1 Change Item
The supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type. (Refer to [SCV types (SV1, SV2)] on P1-7.)
to Fuel Tank
to Fuel Tank
Needle Valve
Armature
Return Spring
Valve Body
Solenoid
Q004459E
1 7
Operation Section
Cylinder
Cylinder
Small Opening
Cylinder
Large Opening
Q004460E
Operation
Operation Section
1 8
3. RAIL
3.1 Change Item
Beginning from August 2006 model vehicles, a pressure discharge valve is used in place of the rail pressure limiter. The engine ECU control and an actuation circuit (EDU) control the pressure discharge valve.
Q004461E
1 9
Operation Section
4. INJECTOR
4.1 Change Items
The injectors used with the 1KD-FTV and 2KD-FTV engines have been changed from the G2 type to the G3 type. In comparison to the G2 type injector, the G3 type injector has the following characteristics: The nozzle shape, and shape of the high-pressure seal service have been changed, resulting in a more high-pressure resistant structure. The G3 injector is more highly responsive due to changes to the nozzle and solenoid valve. In consideration of the mounting measurements, the overall length for the 295050-008# injector (for use with cylinders 1 and 2 in the DYNA) has been made shorter by 5.5 mm.
SM295050-018# SM295050-019#
295050-008#
Q004462E
Operation Section
1 10
QR Codes (
9.9 mm)
QR Codes (
9.9 mm)
295050-008#
Q004463E
The injection quantity correction points contained in the injector QR code are shown in the figure below.
180 MPa 140 MPa
Injection Quantity Q
Correction 12 Points
1 11
Operation Section
Pilot Injection 1
Pilot Injection 2
(2) Goal
Microinjection quantity learning control is used to accomplish the following: 1) to minimize injection quantity deviations due to injector deterioration over time, and 2) to prevent both engine running noise due to misfires and exhaust smoke.
Operation Section
1 12
Determination for learning conditions Microinjection quantity learning control is performed when the following two engine operations are established: 1) a reduction in vehicle speed, and 2) injection is cut off. In the determination process, the engine ECU then judges whether or not the conditions for learning have been met. The figure below shows the specific details for learning determinations.
Determination Content
Non-injection determination Deceleration determination Clutch position determination *For manual transmission vehicles
Q=0 Determination
Time
Q002593E
Single microinjection operation Under the single microinjection operation process, microinjection is performed once the following items are set: 1) the cylinder for which learning will be performed, and 2) the injection quantity. The figure below shows the specific settings and controls for a single microinjection.
Rail Pressure
Injection Quantity Q
Q=0
Detecting the change in rotational speed via injection In this process, the change in rotational speed can be detected using the set microinjection. The figure below shows the processing for calculating changes in rotational speed.
Processing
Rotational speed change detection Rotational speed change processing
1 13
Operation Section
Correcting the injection pulse width (TQ), and actual injection quantity (Q) characteristics In this process, the actual injection quantity is estimated from the set microinjection, and the change in rotational speed. The actual injection quantity is then corrected such that the value equals the target injection quantity. The figure below shows the processing for the aforementioned corrections.
Q Map Value Actual Injection Quantity
Processing
Estimation of correction quantity from each detected value Reflection of correction quantity
Target Q
TQ
Q002596E
[ REFERENCE ] Learning must be performed manually when either an injector (or injectors), or the engine ECU is replaced. As per the figure below, diagnostic tools are used to perform learning while the engine is operating.
No Load 3000 - 4000 rpm
Idle 1 sec.
Idle
Operation Section
1 14
Command Output
Finally, the optimal emission state is found as shown in the figure below.
Includes Error from Compatible Vehicle Actual Injection Quantity Actual Rotational Speed
Command Output
Q002599E
The total deviation in injection quantity is learned via wide-range injection quantity learning. : Reflected in the main injection quantity
Q004484E
1 15
Operation Section
Operation Section
1 16
DTC Malfunction SAE Code P0182 P0183 P0190 P0191 P0192 P0193 P0200 P0299 P0335 P0339 P0340 P0400 P0405 P0406 P0488 P0489 P0490 P0500 P0503 P0504 P0516 P0517 P0560 P0571 P0575 P0606 P0607 P060A P060B P0617 P0627 P0724 P1229 P1238 P1251 P1264 Indicator Lamp (MIL) Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Fuel Temperature Sensor Low Fuel Temperature Sensor High Rail Pressure Sensor System Abnormality Rail Pressure Sensor Characteristics Abnormality Rail Pressure Sensor Low Rail Pressure Sensor High EDU Circuit Abnormality VNT Closed Abnormality Crankshaft Position Sensor Abnormality Crankshaft Position Sensor Power Flicker Camshaft Position Sensor Open Circuit Exhaust Gas Recirculation (EGR) Flow Volume Abnormality EGR Lift Sensor Low EGR Lift Sensor High EGR Throttle Motor System Abnormality EGR E-VRV Low EGR E-VRV High Vehicle Speed Sensor System Abnormality Vehicle Speed Sensor Power Flicker Noise Stop Lamp Switch System Abnormality Battery Temperature Sensor Low Battery Temperature Sensor High Battery Abnormality Stop Lamp Switch (Open, Short) Cruise Cancel Circuit Abnormality Engine ECU Internal Abnormality Control Module Performance Engine ECU Monitor CPU Abnormality Engine ECU Peripheral Circuit Abnormality Starter Circuit High Supply Pump SCV Abnormality (Open, Shortj Stop Lamp Switch Abnormality Supply Pump Abnormality (Overfeed) Injector Injection Abnormality VNT Abnormality (Power Flicker) VNT Driver Abnormality Detection Item
1 17
Operation Section
DTC Malfunction SAE Code P1271 P1272 P1496 P1497 P1550 P1551 P1552 P1570 P1572 P1575 P1578 P1601 P1602 P1604 P1605 P1607 P1611 P1615 P1616 P1617 P1630 P1631 P2006 P2009 P2010 P2120 P2121 P2122 P2123 P2125 P2127 P2128 P2138 P2226 P2228 P2229 Indicator Lamp (MIL) Yes Yes Yes Yes Yes No No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Pressure Discharge Valve System Abnormality Pressure Discharge Valve (Stuck Closed) Intake Air Temperature Sensor Low Intake Air Temperature Sensor High Battery Current Sensor Abnormality Battery Current Sensor Low Battery Current Sensor High Laser Sensor Abnormality Laser Sensor Optical Axis Misalignment Warning Buzzer Abnormality Brake System Abnormality Injector ID Code Abnormality, Unregistered Battery Low Voltage Poor Start Judgment Unstable Idle Cruise Control CPU Abnormality Internal IC Abnormality DSS1 ECU Communication Abnormality Vehicle Control ECU Communication Abnormality Vehicle Control ECU Abnormality VSC ENG Communication Abnormality (VSC ENG) VSC ENG Communication Abnormality (ENG VSC) Swirl Control Valve Stuck Fully Closed Abnormality Swirl Control Valve VSV Abnormality - Low Swirl Control Valve VSV Abnormality - High Accelerator Position Sensor No. 1 (Open) Accelerator Position Sensor (Out of Range) Accelerator Position Sensor No. 1 (Open) Low Accelerator Position Sensor No. 1 (Open) High Accelerator Position Sensor No. 2 (Open) Accelerator Position Sensor No. 2 (Open) Low Accelerator Position Sensor No. 2 (Open) High Accelerator Position Sensor No. 1/ No. 2 Open Atmospheric Pressure Sensor (Open) Atmospheric Pressure Sensor Low Atmospheric Pressure Sensor High Detection Item
Operation Section
1 18
DTC Malfunction SAE Code P245C P245D P2501 P2563 P2564 P2565 P2588 P2589 U0100 U0101 U0122 U0123 U0126 U0235 U1102 U1104 Indicator Lamp (MIL) Yes Yes Yes Yes Yes Yes Yes Yes EGR Cooler Bypass Actuation VSV Low EGR Cooler Bypass Actuation VSV High Alternator Abnormality VNT Position Sensor Characteristics Discrepancy VNT Position Sensor 1 Open VNT Position Sensor 1 Short VNT Position Sensor 2 Open VNT Position Sensor 2 Short Vehicle Control ECU Communication Abnormality TCM ECU CAN Communication Abnormality VSC ENG Communication Abnormality (VSC ENG) Yaw Rate Sensor Communication Abnormality Steering Sensor Communication Abnormality Laser Sensor Communication Abnormality (Sensor Vehicle ECU) Laser Sensor Communication Abnormality (Vehicle ECU Sensor) DSS1 ECU Communication Abnormality Detection Item
1 19
Operation Section
7. ENGINE ECU
7.1 LAND CRUISER PRADO
Main Relay MREL 12V
15A Fuse-EFI
140 +B 143 +B2 139 BATT 13 2 3 9 E1 E01 E02 ME01 PCV+ 6 PCV12
LUSL 41
Engine Earth
Engine Earth OBDII Check Connector 109 WFSE VCPA VPA EPA VCP2 VPA2 EPA2 VNVC VNA VNE2 VCEG EGLS EEGL VCPM PIM EPIM VCVL VLU1 EVLU VCS1 PCR1 E2S1 VCS2 PCR2 E2S2
ALT 31
Alternator
+B MAF Meter
135 Accelerator Position Sensor 137 (Main) 134 133 Accelerator Position Sensor 136 (Sub) 132 65 VNT Position Sensor 83 64 44 EGR Lift Sensor 81 45 66 82 MAP Sensor 47 62 Diesel Throttle Position Sensor 80 63 51 Rail Pressure Sensor 53 (Main) 52 50 Rail Pressure Sensor 85 (Sub) 68
W 105
IREL 127
MIL
IG2 +B BATT
EDU Relay
GREL 27
Glow Plug Relay
EDU
54 VG Intake Air Temperature Sensor (Intake Manifold) Fuel Temperature Sensor Coolant Temperature Sensor Intake Air Temperature Sensor (built into MAF Meter) 55 86 69 87 70 88 71 89 72 E2G THIA ETHI THF ETHF THW ETHW THA ETHA
SCV 14 SCV2 15 ECBV 16 EGR 10 EGRC 58 EGR Cut VSV (36 ACM 144
VSV
Q004466E
Swirl Control Valve (29 at 20 ) Swirl Control Valve 2 (29 at 20 ) EGR Cooler Bypass VSV (29.7 at 20 ) E-VRV (12 at 20
at 20 )
Operation Section
1 20
Cancel
Main
Set
Crankshaft Position Sensor Shield Camshaft Position Sensor IG2 BATT IGSW Stop Lamp Relay
With 275900-048#, -049#, -050#
Brake Switch
Engine Earth
121 ST1- With 275900-045#, -046#, -047# 120 STP 111 IGSW CAN+ 19 ECT ECU CAN- 22
IG1 IG2
46
24
PSW
ID Code Box
4WD ECU
98 L4
Body Earth
100 34 103
1 21
Operation Section
1 7 13
2 8 14
3 9 15
4 10 16
5 11 17
6 12 18
19 20 21 22 23 24 25 26 39 40 41 42 43 56 57 58 59 60 73 74 75 76 77
27 28 29 30 31 32 44 45 46 47 48 49 61 62 63 64 65 66 78 79 80 81 82 83
33 34 35 36 37 38 50 51 52 53 54 55 67 68 69 70 71 72 84 85 86 87 88 89
90 91 92 93 94 95 98 99 100101 102103 106107108109 110 111 114 115 116 117 118119 122123124125 126127 130131132133 134135
Q002653
Operation Section
1 22
7.2 DYNA
15A Fuse-EFI 12V Main Relay MREL 139 13 2 3 Engine Earth OBDII Check Connector Accelerator Position Sensor (Main) 109 135 137 134 133 136 132 44 MAP Sensor Rail Pressure Sensor (Main) Rail Pressure Sensor (Sub) +B 82 47 53 50 85 68 54 Diesel Throttle Position Sensor MAF Meter 89 55 80 81 Intake Air Temperature Sensor (Intake Manifold) 86 Coolant Temperature Sensor 88
With 275900-053# Battery Fluid Temperature Sensor 84
140
+B BATT E1 E01 E02 WFSE VCPA VPA EPA VCP2 VPA2 EPA2 VC PIM EPIM PCR1 VCS2 PCR2 E2S2 VG THA E2G VLU1 EGLS THIA THW IREL 127 EDU Relay +B
With 275900-053#
ALT 31
With 275900-053#
Alternator
RLO 30 W
105 MIL Glow Indicator
IG2
GIND 106
LOUT 116
LED
GREL 27
Glow Plug Relay
MREL 126
THB
OILM 91
Fuel Temperature Sensor 87 45 THF E2
Q004468E
1 23
Operation Section
+B Clutch Switch 46 CLSW TACH 104 56 39 57 40 IGSW 111 121 BATT Brake Switch
SCV 14 Swirl Control Valve (29 at 20 ) ECBV 16 EGR Cooler Bypass VSV (29.7 at 20 )
E-VRV(12 at 20
Meter
#3 37 #2 36 #1 35 PRD 33 EDU
120
Heat Amplifier
108 HSW
EGR 10
A/C Amplifier
125
AC1
at 20 )
117 THWO ACT 114 34 INJ1 CANH 94 CANL 95 J/C A/C Amplifier
103
SPD
EC 145 Starter Relay 128 110 Test Connector STA Body Earth TC EOM 118
Q004469E
Operation Section
1 24
1 7 13
2 8 14
3 9 15
4 10 16
5 11 17
6 12 18
19 20 21 22 23 24 25 26 39 40 41 42 43 56 57 58 59 60 73 74 75 76 77
27 28 29 30 31 32 44 45 46 47 48 49 61 62 63 64 65 66 78 79 80 81 82 83
33 34 35 36 37 38 50 51 52 53 54 55 67 68 69 70 71 72 84 85 86 87 88 89
90 91 92 93 94 95 98 99 100101 102103 106107108109 110 111 114 115 116 117 118119 122123124125 126127 130131132133 134135
Q002653
1 25
Operation Section
7.3 IMV
15A Fuse-EFI 12V Main Relay 111 +B 121 MREL 74 BATT 35 E1 1 E01 2 E02 Engine Earth 128 WFSE OBDII Check With MA275900-059# Connector
With MA275900-058#, -059# RB275900 -066#
(111 )
129 SIL
ECT
Without MA275900-059#
+B Accelerator Position Sensor (Main) MAP Sensor MAF Meter Rail Pressure Sensor (Main)
PI 73
Cruise Indicator
Intake Air Temperature Sensor 25 THIA Coolant Temperature Sensor 26 THW 57 VG 68 VLU 64 EGLS Fuel Temperature Sensor Air Temperature Sensor 33 THF 31 THA
IG2
IG2
EDU Relay
E-VRV (12 at 20
+B +B
126 CCS 41 34 65 132 E2S E2 EVG EPA2 GREL 114 (194 ) Glow Plug Relay
133 EPA
Q004471E
Operation Section
1 26
Crankshaft Position Sensor Camshaft Position Sensor IG2 Brake Switch BATT
With MA275900-058#, -059# RB275900-066#
18 NE+ 58 GECBV 42
+B
28 NE66 G+
EGRC 43
IGSW
at 20 )
TACH 108 #4 24 #3 23 #2 22 #1 21
IG1
82 D D Switch
SCV 10
IG1
SCV2 11
EDU
A/C Amplifier A/C Amplifier A/C Amplifier A/C Amplifier Oil Monitor Immobilizer Immobilizer Viscous Amplifier Viscous Amplifier Alternator
102 IMI 103 IMO 79 VCH 72 VCT 17 ALT Starter Relay 105 STA
Q004472E
1 27
Operation Section
35 36 37 38 39
40 41
70 71
72 73 74 75
105 106 107 108 109 110 111 112 113114 115116 117 118 119 120121 122 123 130 131 124125126127128129 132133 134135
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
42 43 44 45 46 47 48 49 50 51 52 53 54 55 62 63 56 57 64 65 58 59 60 61 66 67 68 69
Q004470E