Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Isi
Klik pada Sub Seksi
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Slide 1
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Model Outline KD Series Engine Chassis Body Body Electrical

Keseluruhan Mesin
Kelengkapan Mesin ________________________________________
Mekanisme Katup
Sistem Pelumasan
Sistem Intake dan Exhaust
Common-rail System
Sistem Bahan Bakar
________________________________________
Sistem Pengisian
Sistem Serpentine Belt Drive
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Slide 2
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Model Outline KD Series Engine Chassis Body Body Electrical

Keseluruhan Mesin
2KD-FTV
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– Mesin Diesel TOYOTA D-4D, 2.5 liter, in-line
4-cylinder, 16 valve DOHC dengan turbocharger
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Slide 3
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2KD-FTV

Model Outline KD Series Engine Chassis Body Body Electrical

Keseluruhan Mesin
Spesifikasi 2KD-FTV
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2KD-FTV 2L

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Item
(KIJANG INNOVA) (KIJANG)
Jumlah Silinder dan
4-Cylinder, In-line 
Susunan
16-Valve DOHC, 8-Valve OHC,

________________________________________
Mekanisme Katup
Belt & Gear Drive Belt Drive
Sistem Bahan Bakar Common-Rail Type Distributor Type

Slide 4 Intercooler
Displacement
Tanpa 

cm3 (cu. in.)

Bore x Stroke
2,492 (152.2)

92.0 x 93.8
2,446 (149.3)

92.0 X 92.0
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mm (in.) (3.62 x 3.69) (3.62 X 3.62)
Rasio Kompresi 18.5 22.2 : 1
Max. Output [EEC]
kW / rpm
75 @ 3,600 61 @ 4,200 ________________________________________
Max. Torque [EEC] 200 @ 1,400 ~ 3,200
160 @ 2,400
N·m / rpm 260 @ 1,600 ~ 2,400 *
*: High Version
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Model Outline KD Series Engine Chassis Body Body Electrical

Keseluruhan Mesin
Fitur
________________________________________
– Ruang Mesin
Intercooler (untuk Thailand)
Rotary Solenoid Type
Diesel Throttle ________________________________________
________________________________________
Slide 5
________________________________________
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Photo: 1KD-FTV

SLLC
Fuel Filter
•Fuel filter warning (Sumbatan)
•Tipe penggantian elemen saja
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Hal. 1 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Kelengkapan Mesin
Piston
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– Dengan penggunaan direct injection, ruang bakar
diletakan pada piston
________________________________________
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Combustion
Chamber

Slide 6 Ni-resist
Cast Iron
Ring Carrier
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Cooling
Channel
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2KD-FTV

Model Outline KD Series Engine Chassis Body Body Electrical

Mekanisme Katup
Timing Belt
________________________________________
– Timing Belt, penggantian setiap 150.000 km

Camshaft
Oil Pump Drive Gear ________________________________________
Timing Crankshaft Timing Gear
Pulley No. 2

Timing
Supply Pump Drive Gear
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Slide 7 Belt

Automatic
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Belt

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Tensioner

Camshaft
Timing
Pulley No. 1

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Vacuum Pump Drive Gear

Idle Gear

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Pelumasan
Sistem Pelumasan
________________________________________
– Keseluruhan
• Pelumasan tipe tekanan penuh dan semua oli
melewati pendingin dan saringan ________________________________________
________________________________________
Slide 8
Oil Filter ________________________________________
Oil Cooler
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Oli mesin dan saringan oli
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– Jarak Maintenance

Indonesia
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Mesin 2KD-FTV 2L
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Slide 9
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Normal Setiap 5,000km atau 6 bulan 
Oli
Penggantian

Mesin
Parah Setiap 2,500km atau 3 bulan 

Saringa
n Oli
Normal Setiap 10,000km atau 12 bulan ________________________________________
Parah Setiap 5,000km atau 6 bulan

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Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Intake dan Exhaust
Intake Shutter Valve
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– Rotary solenoid type intake shutter valve digunakan
untuk memperbaiki EGR
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Kondisi Posisi Intake Shutter Valve

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Purpose Position Sensor
Mesin Katup
Terbuka Mengurangi
Starting
Slide 10
Penuh asap diesel
Tertutup Mengurangi suara
Stop

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Penuh dan getaran

Air flow

Intake Shutter Valve ________________________________________

Rotary Solenoid
type Motor ________________________________________

Hal. 2 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Intake dan Exhaust
Intake Shutter Valve
________________________________________
– Konstruksi
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Rotary Solenoid
Type Motor

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Intake Shutter Valve
Position Sensor

Slide 11 Magnet
Steel Layer

Hall IC ________________________________________
Magnet
Magnet
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Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Intake dan Exhaust
Intake Manifold
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• 2 intake port dengan bentuk berbeda dari intake
manifold ke cylinder head
 Untuk mengoptimalkan “swirl” (putaran) ________________________________________
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Slide 12
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Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Intake dan Exhaust
Turbocharger (Hanya 2KD)
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– Ringan, kompak dan berkemampuan tinggi
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Slide 13
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Waste Gate Actuator

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Valve for Waste

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Gate Valve

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Umum
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NE Signal
G Signal
Various
Engine
ECU
EDU ________________________________________
Pressure
Signals Limiter

Fuel Common-rail ________________________________________

Slide 14
Pressure
Sensor

Pressure
Switch Injector ________________________________________
Fuel

________________________________________
Filter

SCV
Supply Pump Fuel Filter
Fuel Tank Warning Light

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Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Fitur
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NE Signal
G Signal
Engine
ECU
EDU
Injector
________________________________________
Various compensation
Max. 160MPa Pressure
Signals code
Limiter

HP3 Type
Supply Fuel Common-rail ________________________________________
Slide 15 Pressure
Pump Sensor

Pressure
Switch Injector ________________________________________
Fuel

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Filter

SCV
Supply Pump Fuel Filter Warning light
Replacement
filter Fuel Tank Warning Light for fuel filter
Detects clogging and
element only

________________________________________
filter fuel sedimenter
clogging

Hal. 3 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Umum
________________________________________
– System ini dapat memberikan tekanan injeksi tinggi di
setiap kecepatan mesin.
NE Signal EDU
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Engine
(Operates injector
G Signal ECU at high-speed)

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Pressure
Various Limiter
Signals Common-rail

Slide 16
(Stores high-pressure fuel)
Fuel Pressure
Sensor

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Injector
(Injects high-pressure fuel)

Supply Pump
SCV ________________________________________
(Generates high-pressure fuel) Fuel Tank

: High-pressure (Max. 160 MPa)

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Model Outline KD Series Engine Chassis Body Body Electrical

Referensi
Umum
________________________________________
– Keuntungan common-rail system
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Tekanan injeksi, volume dan timing
dikontrol secara elektronik Kontrol mesin yg akurat

Bahan bakar tekanan tinggi Atomisasi lebih baik

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Slide 17
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Menyimpan bahan bakar Injeksi tekanan tinggi
tekanan tinggi disemua kecepatan mesin

• High performance dan fuel economy

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• Suara dan getaran rendah
• Emisi lebih bersih ________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
System Outline
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Common-rail Diesel Conventional Diesel
Constant high pressure
Common-rail Pressure
Sensor
Instantaneously high pressure
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System
SCV

ECU
Timer
Governor
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Slide 18 Injector Pump
Injection

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Supply Pump Nozzle
Injection Volume
ECU (Injector) Pump (Governor)
Control
Injection Timing
ECU (Injector) Pump (Timer)
Control
Injection Pressure
Control
Supply Pump (SCV)
According to rotational speed
and injection quantity
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Pressurization Supply Pump Pump

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Distribution Common-rail Pump
Injection Pressure Max. 160 MPa Approx. 15 MPa

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Lokasi
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Depan

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Injection Pipe Injector

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Slide 19 Fuel Inlet Pipe

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Supply Pump
Common-rail
•Fuel Pressure Sensor
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•Pressure Limiter
•SCV (Suction Control Valve)

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•Fuel Temp. Sensor

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Mengirimkan tekanan tinggi ke common-rail
– Digerakkan oleh crankshaft
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To Common-rail
(Outlet)
From Fuel Filter
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Slide 20 (Inlet)

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To Fuel Tank

________________________________________
(Return)

SCV
(Suction Control Valve)

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Hal. 4 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
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– Konstruksi
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Check Eccentric and Delivery

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Valve Ring Cam Valve

Slide 21 Plunger
Feed

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Pump

Fuel
Temp.
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Sensor
SCV (Suction
Control Valve)
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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Konstruksi
To fuel tank
(return) ________________________________________
________________________________________
Slide 22 Ring Cam

Plunger
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Eccentric
Cam ________________________________________
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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Aliran Bahan Bakar
To common-rail
________________________________________
________________________________________
Slide 23
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Dari Fuel
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Tank

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Aliran Bahan Bakar (referensi)
________________________________________
________________________________________
Slide 24
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Click!
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Movie

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
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– Penghisapan dan pemompaan
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Plunger A: Hisap Plunger A: Pompa
Plunger B: Pompa Plunger B: Hisap
Check
Valve
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Slide 25 Plunger A

SCV
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Plunger B
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: Dari Feed Pump : Ke Common-rail ________________________________________

Hal. 5 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Penghisapan dan pemompaan
________________________________________
________________________________________
Slide 26
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Click!
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Movie

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Kerja Fuel control (bukaan SCV kecil)
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Fuel ________________________________________
Slide 27 Pumping
Mass

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Kerja Fuel control (bukaan SCV besar)
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Slide 28 Fuel
Pompa
Mass
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Model Outline KD Series Engine Chassis Body Body Electrical

Referensi
Supply Pump
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– Plunger mebuat Negative

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Pressure
kevacuuman untuk
menghisap bahan bakar
sampai gelembung hilang

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Slide 29
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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Kerja Fuel control (bukaan SCV kecil)
________________________________________
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Slide 30
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Click!
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Movie

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Hal. 6 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Kerja Fuel control (bukaan SCV besar)
________________________________________
________________________________________
Slide 31
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Click!
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Movie

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Supply Pump
________________________________________
– Bukaan SCV mengontrol volume pemompaan untuk
mengontrol tekanan bahan bakar
[Fuel Pressure Control]
________________________________________
Fuel Pressure
Sensor

________________________________________
Slide 32
SCV
Common-rail
pressure
(Feedback) ________________________________________
Controls Crankshaft
SCV Perhitungan Position Sensor
opening target injection
pressure
Accelerator Pedal
________________________________________
Position Sensor
Engine ECU

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Common-rail
________________________________________
– Menyimpan tekanan tinggi (Max. 160 MPa) yang
dikirim oleh supply pump
Pressure
Limiter
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Fuel
Pressure
________________________________________
Slide 33 Sensor

________________________________________
Common-rail ________________________________________
Dari
Ke Injector Ke Fuel Tank
Supply Pump
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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Common-rail
________________________________________
– Fuel pressure sensor
• Mendeteksi internal fuel pressure di common-rail
________________________________________
________________________________________
Output characteristic
Sensor Tip
Output Voltage (V)

Slide 34 4.04

2.44

1.0
________________________________________
0 90 190
Common-rail Pressure (MPa) ________________________________________
Common-rail
Pressure

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Injector
________________________________________
– Injeksi tekanan tinggi untuk atomisasi yang lebih baik

Injector
Compensation
________________________________________
Code
Kembali ke

________________________________________
Fuel Tank Dari Common-rail

Slide 35
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________________________________________
0.14 mm
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Hal. 7 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Injector
________________________________________
– Konstruksi

Solenoid Coil ________________________________________

Dari
Kembali ke
Fuel Tank Common-rail
________________________________________
Slide 36
Piston ________________________________________
Nozzle
Spring
________________________________________
Nozzle
Needle
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Injector
________________________________________
– Dikontrol signal dari ECU

Solenoid
________________________________________
Solenoid

Small
TWV
________________________________________
Slide 37 From
Orifice Return

Common-rail Large
Orifice ________________________________________
________________________________________
Click!
Movie

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Injector
________________________________________
– Pilot injection mengurangi NOx dan suara mesin

Main
________________________________________
Injection Pilot
Volume

NOx and
engine noise
________________________________________
Slide 38
Heat
Release
Value
________________________________________
TDC TDC ________________________________________
Pilot Conventional
Injection Control Injection Control

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Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
EDU (Electronic Driver Unit)
________________________________________
– Mengendalikan injectors saat kecepatan tinggi
________________________________________
EDU

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Battery High
DC / DC Voltage
Converter
Slide 39 Command
Pulse
IJT
#1-4
Control
________________________________________
Circuit High-speed
operation

________________________________________
IJF
Confirmation
Engine Pulse Injector
ECU

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Diagnosis
________________________________________
– DTC untuk common-rail system

DTC No. Item Pendeteksian

Area Kerusakan Detection Condition

Area Kerusakan
Fail-safe
________________________________________
P0087 Fuel Rail/System Tekanan - •Open atau short pada fuel pressure sensor
terlalu rendah circuit •Fuel pressure sensor •Engine ECU

________________________________________
(49)
P0088 Fuel Rail/System Tekanan – •Short pada supply pump (SCV) circuit •Supply
(78) terlalu tinggi pump (SCV) •Engine ECU

Slide 40 •Jalur bahan bakar high pressure

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•Open pada short pada EDU circuit
P0093 Terdeteksi Bahan Bakar
•Open atau short pada injector circuit
(78) bocor, bocor besar
•Supply pump •Common-rail •Injectors •EDU
•Engine ECU

P0190 Fuel Rail Pressure Sensor

(49)
P0192
(49)
Circuit Malfunction

Fuel Rail Pressure Sensor

Circuit Low Input
•Open atau short pada fuel pressure sensor
circuit
•Fuel pressure sensor
________________________________________
•Engine ECU
P0193 Fuel Rail Pressure Sensor
(49) Circuit High Input
________________________________________

Hal. 8 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Diagnosis
________________________________________
– DTC untuk common-rail system

DTC No. Item Pendeteksian

Trouble Area Kondisi Pendeteksian

Kondisi Pendeteksian
Fail-safe
________________________________________
P0087 Fuel Rail/System Pressure - Fuel pressure sensor output voltage nilainya
Terlalu rendah tidak berubah

________________________________________
(49)
P0088 Fuel Rail/System Pressure -
Tekanan melebihi 200 MPa (2039 kgf/cm2)
(78) Terlalu tinggi

Slide 41 Perbedaan tekanan common-rail sebelum dan

________________________________________
Terdeteksi kebocoran pada
P0093 setelah injeksi bahan bakar berbeda jauh dari
sistem Bahan Bakar – Bocor
(78) besar
yang sudah di hitung ECU sebelum dan sesudah
injeksi

P0190 Fuel Rail Pressure Sensor Fuel pressure sensor output voltage 0.55V atau
(49)
P0192
(49)
Circuit Malfunction

Fuel Rail Pressure Sensor

Circuit Low Input
kurang, atau 4.9V atau lebih selama 0.5 sec.

Fuel pressure sensor output voltage 0.55V atau

kurang selama 0.5 sec.
________________________________________
P0193 Fuel Rail Pressure Sensor Fuel pressure sensor output voltage 4.9V atau
(49) Circuit High Input lebih selama 0.5 sec.

1 trip detection logic untuk semua DTC

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Diagnosis
________________________________________
– DTC untuk common-rail system

DTC No. Item Pendeteksian

Trouble Area Detection Condition

Fail-safe
Fail-safe
________________________________________
P0087 Fuel Rail/System Pressure -
(49) Terlalu rendah

P0088
(78)
Fuel Rail/System Pressure -
Terlalu tinggi
Membatasi power mesin
________________________________________
Slide 42
P0093
(78)
Terdeteksi kebocoran sistem
Bahan Bakar – Bocor besar
Membatasi power mesin selama 1 min.,
kemudian mematikan mesin ________________________________________
P0190 Fuel Rail Pressure Sensor
(49)
P0192
(49)
Circuit Malfunction

Fuel Rail Pressure Sensor

Circuit Low Input
Membatasi power mesin
________________________________________
P0193 Fuel Rail Pressure Sensor
(49) Circuit High Input
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Diagnosis
________________________________________
– DTC untuk common-rail system

DTC No. Item Pendeteksian

Area Kerusakan Detection Condition

Area Kerusakan
Fail-safe
________________________________________
•Open atau short pada EDU circuit
P0200
(97)
Injector Circuit / Open
•EDU
•Injector
•Engine ECU
________________________________________
Slide 43
________________________________________
•Open atau short pada (SCV) circuit
P0627 Fuel Pump Control Circuit
•SCV
(78) / Open
•Engine ECU

•Short pada supply pump (SCV) circuit

P1229

________________________________________
Fuel Pump System •Supply pump (SCV)
(78)
•Engine ECU

Injector Correction
P1601 •Injector compensation code
Circuit Malfunction
(89) •Engine ECU
(EEPROM)
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Diagnosis
________________________________________
– DTC untuk common-rail system
Trouble Area Kondisi Pendeteksian Fail-safe

Open atau short pada EDU atau injector circuit.

________________________________________
Setelah mesin hidup, tak ada injection
DTC No. Injector Circuit / Open confirmation (INJF) signal dari EDU ke engine

________________________________________
ECU, walau engine ECU mengirim injection
command (IJT) signal ke EDU

P0200
Slide 44
Fuel Pump Control Circuit / Open atau short pada suction control valve
(97) Open circuit lebih dari 0.5 sec.

P0627
(78)
Fuel Pump System
Terlalu banyak bahan bakar:
Tekanan bahan bakar melewati target
walaupun ECU telah menutup SCV.
________________________________________
P1229 Injector Correction Circuit
Injector compensation code tidak ter-register
(78) Malfunction (EEPROM)

P1601
Injector Circuit / Open
Open atau short pada EDU atau injector circuit.
Setelah mesin hidup, tak ada injection
confirmation (INJF) signal dari EDU ke engine
________________________________________
(89) ECU, walau engine ECU mengirim injection
command (IJT) signal ke EDU

1 trip detection logic untuk semua DTC

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Diagnosis
________________________________________
– DTC untuk common-rail system

DTC No. Detection Item

Trouble Area Detection Condition

Fail-safe
Fail-safe
________________________________________
P0200
(97)
Injector Circuit / Open
________________________________________
Slide 45
P0627
(78)
Fuel Pump Control Circuit
/ Open
Membatasi Power Mesin
________________________________________
P1229

________________________________________
Fuel Pump System
(78)

Injector Correction
P1601
Circuit Malfunction -
(89)
(EEPROM)
________________________________________

Hal. 9 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail System
Service Point untuk Common-rail System
________________________________________
– Inisialisasi dan kalibrasi Supply Pump
– Penggantian Common-rail
– Program ulang injector compensation code ________________________________________
– Penggantian parts baru
– Penggantian pipa baru
– Periksa kebocoran bahan bakar (Leakage Pipe No.1 /
Sistem Bahan Bakar)
________________________________________
Slide 46
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Inisialisasi dan kalibrasi Supply Pump
________________________________________
– Jika mengganti supply pump atau engine ECU, perlu
inisialisasi dan kalibrasi untuk engine ECU
________________________________________
EEPROM

supply pump discharge

characteristic data ________________________________________
Slide 47 Inisialisasi
dan Kalibrasi

Penggantian
Data karakteristik output
supply pump BARU
________________________________________
________________________________________
Inisialisasi hanya dibutuhkan jika mesin tak bisa hidup setelah penggantian ________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Supply Pump Initialization and Calibration
________________________________________
– Prosedur

Setelah
Penggantian,
Engine
stop
Inisialisasi
CG TC
________________________________________
for 3 min.

IG Turn Short
DLC3
IG ON
Resetting
IG OFF
________________________________________
Slide 48
________________________________________
Start engine Start engine

Kalibrasi Learning
THW > 60 °C

________________________________________
THF > 20 °C

Warm-up Idling for 1 min. IG OFF

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Common-rail Replacement
________________________________________
– Common-rail tak boleh di bongkar
(Penggantian Assembly)
________________________________________
Jangan ________________________________________
Slide 49 Fuel Pressure
Dibuka !
Sensor
________________________________________
Pressure

________________________________________
Limiter

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Jika injector atau ECU mesin diganti, perlu
memprogram ulang nilai injector compensation
Ganti Nomor
________________________________________
Injektor Injektor baru

Program ulang
data ________________________________________
Slide 50 ECU mesin

Ganti ECU
Masukan
nomor ________________________________________
mesin

________________________________________
Semua nomor
injektor

________________________________________

Hal. 10 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Garis besar proses registrasi

Ketika menganti injector(s) Ketika mengganti ECU ________________________________________

Catat data compensation code
Ganti injector(s)
code data
________________________________________
Slide 51 Masukan code compensation
baru secara manual

________________________________________
Ganti ECU
Input
Set
Masukkan compensation codes yg
sudah dicatat
Saved data

________________________________________
Hapus DTC P1601 Hapus DTC P1601

Registrasi selesai Registrasi selesai

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 52
Save the
Compensation
Codes
________________________________________

Click!
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
Select
________________________________________
Powertrain

Engine and ECT

________________________________________
Slide 53 Utility

Injector Compensation
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 54
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 55 “Read
Compensation

________________________________________
Code”

________________________________________
________________________________________

Hal. 11 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 56
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 57 Select
cylinder No.

________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 58
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 59
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 60
“Save”
________________________________________
________________________________________
________________________________________

Hal. 12 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 61 Periksa bahwa
compensation code
benar

________________________________________
“Save”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 62
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
Selesai
menyimpan No.1
cylinder’s injector
compensation code
________________________________________
Slide 63
________________________________________
Baca dan simpan
injector
compensation
codes yang lain
Selesai
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Catat injector compensation codes
(sebelum mengganti engine ECU)
________________________________________
________________________________________
Slide 64
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 65
Set the
Compensation
Codes
________________________________________

Click!
________________________________________
________________________________________

Hal. 13 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
Select
________________________________________
Powertrain

Engine and ECT

________________________________________
Slide 66 Utility

Injector Compensation
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 67
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________

“Set
________________________________________
Slide 68 Compensation
Code”

________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 69
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 70 Select
cylinder No.

________________________________________
________________________________________
________________________________________

Hal. 14 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 71
________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 72
“Input”
(Input manually)
“Open”
(Input saved data) ________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
Input
Nomor 1

________________________________________
Slide 73 30

“Input”
(Input manually) ________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
Input
Nomor 1

________________________________________
Slide 74 “OK”
30

________________________________________
01BBC0DFED00E70D000000000000A2

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 75
“Open”
________________________________________
________________________________________
________________________________________

Hal. 15 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 76
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
Periksa bahwa ________________________________________
Slide 77 compensation code
benar

________________________________________
“Next”

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 78
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
Selesai setting
No.1 cylinder’s
injector
compensation code
________________________________________
Slide 79
________________________________________
Set injector
compensation
codes yang
Selesai
________________________________________
lainnya

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Program ulang Injector Compensation Code
________________________________________
– Registrasi injector compensation codes
(setelah penggantian)
________________________________________
________________________________________
Slide 80
________________________________________
________________________________________
________________________________________

Hal. 16 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Penggantian parts baru
________________________________________
– Parts yang tidak boleh dipakai ulang (huruf merah)
Injector
Nozzle
Holder Seal
________________________________________
Back-up Ring

O-ring
________________________________________
Slide 81 Nozzle Seat Head Cover

Gasket
________________________________________
O-ring

________________________________________
Leakage Pipe
Supply Pump

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Penggantian pipa baru
________________________________________
– Ganti dengan pipa baru jika mengganti komponen-
komponen berikut
Injection
________________________________________
Pipes

Komponen yang
diganti
Pipa yang
diganti ________________________________________
Slide 82 • Injector
• Common-rail
Injection

________________________________________
Pipes
• Cylinder Head

•Supply Pump
•Common-rail
•Cylinder Block Fuel Inlet

________________________________________
•Cylinder Head Pipe
•Cylinder Gasket
•Gear Case

________________________________________
Fuel Inlet Pipe

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Periksa kebocoran (Nozzle Leakage Pipe)
________________________________________
– Tahan pada tekanan 250 kPa (2.5 kgf /cm2, 35.5 psi)
selama 60 detik dan periksa tidak ada gelembung
SST
________________________________________
(09268-45014)
Oles dengan air sabun pada
sambungan, periksa ada
[90405-06167]

________________________________________
nya gelembung
Nozzle
Leakage
Pipe

Slide 83
________________________________________
250 kPa

Lepas ________________________________________
SST (09992-00242) Check Valve
(Part No. 23122-27010)
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Periksa kebocoran (Sistem Bahan Bakar)
________________________________________
1, Mesin berhenti
Tak ada kebocoran
________________________________________
2, Start mesin
Tak ada kebocoran
________________________________________
Slide 84 3, Lepas selang balik dari common-rail
Start mesin

Tak bocor (dari selang balik)

________________________________________
4, Dengan Intelligent Tester II, lakukan
Fuel Leak Test (Active Test) ________________________________________
Tak ada kebocoran

Sistem Bahan Bakar

normal ________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Power Balance Check
________________________________________
– Gunakan Intelligent Tester II (Active Test) untuk
pemeriksaan power balance
________________________________________
Active Test
•Injector Cut
•Injector Cut
#1
#2
________________________________________
Slide 85 •Injector Cut #3
•Injector Cut #4
Tegangan
Tinggi ________________________________________
________________________________________
Jangan melepas

________________________________________
konektor injektor

Hal. 17 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Saringan Bahan Bakar
________________________________________
– Hanya mengganti element saringan
Priming
Pump
Fuel Filter
Warning Switch
________________________________________
Dari Fuel Tank
Ke Supply Pump
________________________________________
Slide 86 Fastener Nut

Filter Housing
(Plastic)
________________________________________
Filter Element
________________________________________
________________________________________
Drain Cock

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Saringan Bahan Bakar
________________________________________
– Konstruksi
Priming
Pump
Fuel Filter
Warning Switch
________________________________________
Dari Fuel Tank Ke Supply Pump ________________________________________
Slide 87 Fastener Nut

Filter Element Filter Housing

(Plastic)
________________________________________
________________________________________
Fuel Sedimenter Level
Warning Switch

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Fuel Filter Warning
________________________________________
– Tersumbat nya Saringan Bahan Bakar dideteksi oleh
Fuel Filter Warning Switch
Fuel Filter
________________________________________
Warning Switch Fuel Filter
Warning Light

________________________________________
Slide 88
Tersumbat ________________________________________
Combination Meter

Fuel Filter
________________________________________
- Jarak Penggantian Saringan Bahan Bakar -
Jika fuel filter warning light menyala ________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Fuel Filter Warning
________________________________________
– System Diagram
Combination Meter ________________________________________
Vehicle Speed
Sensor
Fuel Filter
Warning Switch
Meter
ECU ________________________________________
Slide 89 Fuel Filter
Warning Light

Ke Supply Pump
________________________________________
Filter Element

________________________________________
Fuel Filter Fuel Sedimenter Level Warning Switch

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Fuel Filter Warning
________________________________________
– Fuel filter warning switch akan OFF saat tekanan
outlet filter menurun
Fuel Filter Fuel Filter
________________________________________
Warning Warning

________________________________________
Switch Switch
ON Meter OFF Meter
ECU ECU

Slide 90 Diaphragm

Ke Supply Pump

Filter Element
Ke Supply Pump

Negative
________________________________________
Pressure

Normal Fuel Filter Fuel Filter Tersumbat

________________________________________
(Switch: ON) (Switch: OFF)

________________________________________

Hal. 18 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Fuel Filter Warning
________________________________________
– Kondisi warning light untuk fuel filter / fuel sedimenter
________________________________________
Warning
Warning
Method
Prioritas
________________________________________
Slide 91 Sedimenter
Warning
Berkedip
1
________________________________________
Fuel Filter
Warning 2 ________________________________________
ON

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Bahan Bakar
Fuel Filter Warning
________________________________________
– Kondisi Pendeteksian
Setelah pengemudian 30 menit atau lebih ________________________________________
Kondisi Fuel Filter Warning Switch ________________________________________
Slide 92 OFF selama 10
menit atau lebih
atau
Terdeteksi OFF
sebanyak 2 kali

________________________________________
dalam 1 trip

________________________________________
Warning light tetap ON sampai dilakukan reset ________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Jika warning light menyala, ganti elemen Saringan
Bahan Bakar dan reset warning light
________________________________________
Buka elemen saringan

________________________________________
Slide 93
________________________________________
Longgarkan
Tutup Bahan
Bakar ________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Buka elemen Saringan Bahan Bakar
________________________________________
Inlet hose

Fuel
Level ________________________________________
Slide 94
________________________________________
Drain
Cock ________________________________________
Lepas Keluarkan bahan bakar untuk
konektor menurunkan permukaan nya

________________________________________
dan hose

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Buka elemen Saringan Bahan Bakar
________________________________________
Obeng ________________________________________
Slide 95
________________________________________
________________________________________
Longgarkan pengunci Lepas dengan tangan

________________________________________

Hal. 19 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Buka/Pasang Saringan Bahan Bakar element
________________________________________
Element Pasang Saringan
Bahan Bakar

________________________________________
Slide 96
________________________________________
Rumah Element

Pasang O-ring baru

________________________________________
Buka tutupnya, lepas
elemen

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Pasang Saringan Bahan Bakar
________________________________________
Tanda

________________________________________
Tanda

Slide 97
________________________________________
Elemen
baru
________________________________________
Pasang elemen baru dan
pasang tutup filter Kencangkan pengunci sampai

________________________________________
(luruskan tanda) tanda nya lurus

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Pasang Saringan Bahan Bakar
________________________________________
Inlet Hose
________________________________________
Slide 98
________________________________________

Hubungkan
Kencangkan tutup
bahan bakar ________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Pasang Saringan Bahan Bakar / Reset warning light

Reset warning light

________________________________________
________________________________________
Slide 99 dalam
3 detik.

________________________________________
3 - 60 detik

IG ON
OFF

Pasang ________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Fuel Filter Warning
________________________________________
– Pasang Saringan Bahan Bakar / Reset warning light

Keluarkan udara pada

________________________________________
Sistem Bahan Bakar

Slide
pompa
________________________________________
100 Selesai ________________________________________
________________________________________
________________________________________

Hal. 20 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Pengisian
Alternator Pulley
________________________________________
• Untuk menyerap fluktuasi mesin, digunakan one-
way clutch pada pulley　alternator
________________________________________

Slide ________________________________________
101
________________________________________
Spring Sprag
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Pengisian
Alternator Pulley
________________________________________
– Mekanisme penyerapan fluktuasi mesin

One-way
________________________________________
Clutch Crankshaft Pulley
Locked Speed

Slide
One-way
Clutch
Free
________________________________________
102
Alternator
Pulley Speed
________________________________________
Pulley Speed (rpm)

Engine
Fluctuation ________________________________________
Time
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Alternator Pulley
________________________________________
– Gunakan SST, saat membuka atau memasang
alternator pulley
________________________________________
SST (09820-63020):

Slide
2 parts
________________________________________
103
Buka ________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Service Point
Alternator Pulley
________________________________________
– Alternator pulley cap hanya sekali pakai
________________________________________

Slide ________________________________________
104
________________________________________
Alternator Pulley Cap
(Non-reusable Part)

________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Sistem Serpentine Belt Drive
Serpentine Belt Drive
________________________________________
– Single V-ribbed belt
Air Conditioner
Compressor Pulley
Idler Pulley ________________________________________
Water Pump Pulley

________________________________________
Idler Pulley

Slide Alternator Pulley

with Shock
Crankshaft Pulley

105 Absorbing Function

Idler Pulley for

Automatic Tensioner
________________________________________
- jarak penggantian -

2KD-FTV baru
Indonesia
2L
________________________________________
Periksa pada 100,000km pertama,
Periksa setiap 20,000 km atau 24 bulan

________________________________________
periksa setiap 20,000km
- Ganti setiap 40,000km atau 48 bulan

Hal. 21 dari 22
Handout INST – Mesin 2KD

Model Outline KD Series Engine Chassis Body Body Electrical

Referensi
Intake Shutter Valve
________________________________________
– Intake shutter valve position sensor
________________________________________
Magnet

Slide
Hall IC 5
________________________________________

Output Voltage (V)

VC 3.51

106 Engine
ECU
VLU

1
0.71
________________________________________
E2 0
0 20 70 100

________________________________________
(Full Close) (Full Open)
Intake Shutter
Intake Shutter Valve
Valve Position Opening Angle (°)
Sensor

________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Referensi
Accelerator Pedal
________________________________________
– Non-contact type accelerator pedal position sensor

Accelerator Pedal
________________________________________
Position Sensor

Slide ________________________________________
107
________________________________________
________________________________________
________________________________________

Model Outline KD Series Engine Chassis Body Body Electrical

Referensi
Accelerator Pedal
________________________________________
– Using magnet dan hall IC
________________________________________
VCP1
Magnets

Slide
VPA1
________________________________________
Output Voltage (V)

EP1 5

108 VPA2

________________________________________
VCP2

Hall
IC VPA2
VPA1
EP2 0

Accelerator
Pedal Position
Engine
ECU
Full Close Full Open
Accelerator Pedal Depressed Angle ________________________________________
Sensor

________________________________________

Hal. 22 dari 22