Transcript Engine Control System

Verso-s
1ND-TV gen3 Euro 5
Engine Overall
1ND-TV Engine
Engine
1ND-TV
No. of Cylinders and Arrangement
4-cylinder, In-line
Valve Mechanism
8-valve SOHC,
Chain Drive
Combustion Chamber
Direct Injection Type
Flow of Intake and Exhaust Gases
Cross-flow
Fuel System
Common-rail Type
Displacement [cm3]
1,364
Bore x Stroke [mm]
73.0 x 81.5
Compression Ratio
16.5:1
Max. Output [kW @ rpm]
66 @ 3,800
Max. Torque [Nm @ rpm]
205 @ 1,800 to 2,800
Intake
Valve Timing
Exhaust
1ND-TV
2
Open
4º BTDC
Closed
36º ABDC
Open
44º BBDC
Closed
4º ATDC
Oil Grade
ACEA C2
Fuel Cetane Number
48 or higher
Firing Order
1 –3 – 4 – 2
Emission Regulation
EURO V
Engine Overall
• Cranking Hold Function
• Brake Override System
Features
Rocker Arm
Turbo
Charger
Injector
Vacuum Pump
Supply Pump
•EGR Valve
•EGR Cooler
Common-rail
Throttle Body
After Warm-up
Circulation System
Oil Filter
Oil Level Sensor
Exhaust Manifold Converter
Oil Pressure Sender Gage Assembly
3
Oil Pressure Switching Valve
Oil Pump
Oil Pump
(Electrically
Variable Oil
Pressure Type)
Engine Overall
Specifications
Model
Verso-s
Urban Cruiser
No. of Cylinders and Arrangement
4-Cylinder, In-line

Valve Mechanism
8-Valve SOHC, Chain Drive

Combustion Chamber
Direct Injection Type

Fuel System
Common-rail Type

Displacement [cm3]
1,364

Bore x Stroke [mm]
73.0 X 81.5

Compression Ratio
16.5 : 1

Maximum Output (EEC) [kW @ rpm]
66 @ 3,800

Maximum Torque (EEC) [N·m @ rpm]
205 @ 1,800 to 2,800

Open
4º BTDC

Close
36º ABDC

Open
44º BBDC

Close
4º ATDC

Firing Order
1–3–4-2

Emission Regulation
EURO V
Euro IV
0W-30 or 5W-30 /ACEA C2

Intake
Valve
Timing
Exhaust
Engine Oil
4
Viscosity / Grade
Engine Overall
Main Features [2/2]
Item
Lubrication
System
Cooling System
Fuel System
Feature
An Aluminum Alloy Made Water-cooled Type Oil Cooler is used
(3)
Element Replacement Type Oil Filter is Used
(4)
Oil Pump (Electrically Variable Oil Pressure Type)
is Used
TOYOTA Genuine Super Long Life Coolant (SLLC) is Used
After Warm-up Circulation System is Used
(1), (2)
(4)
(1), (5)
A Common-rail Type Fuel Injection System is Used
(1), (2), (5)
Compensation Value and Data Matrix Code (DMC) Printed Piezo
Type Injector is Used
(1), (2), (5)
A DC Motor Type EGR Valve is Used
Emission
Control System A Water-cooled Type EGR Cooler with Bypass Switching Valve is
Used
(1), (5)
(1), (5)
An Air Flow Meter is Used
(5)
The Non-contact Sensor is Used in The Accelerator Pedal Position
Sensor and Throttle Position Sensor
(1)
Engine Control A Catalyst Support Control is Used
System
A Pilot Injection Control is Used
6
Achieved
Performance
(5)
(1), (2), (5)
A Oil Maintenance Management System is Used
(4)
Brake Override System is Used
(1)
Lubrication System
Overall
• Lubrication circuit is fully pressurized and oil passes through oil
filter
• An electric variable oil pressure type oil pump, which can control
the pressure of the engine oil in 2 stages in accordance with
driving conditions, is used
Oil Grade
ACEA C2
Oil Viscosity (Preferred)
0W-30 or 5W-30
Drain and
Refill
11
w/ Oil Filter
Change
4.1 liters
w/o Oil Filter
Change
3.6 liters
Dry Fill
4.5 liters
Type of Engine Oil Filter
Replaceable Element Type
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• This oil pump can control the engine oil pressure in 2 stages to
reduce energy loss and improve fuel efficiency
Sleeve
Valve
To Engine Parts
Oil Pressure [kPa]
Oil Pressure
Switching Valve
Relief Valve
Relief Valve Spring
13
From
Oil Pan
Opening Pressure
of Piston Oil Jet
Engine Speed [rpm]
Oil Pump
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• Parts Location
Oil Pressure Sender Gage Assembly
Oil Pressure Switching Valve
Oil Pump Assembly
14
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• System Diagram
Engine Coolant
Temperature Sensor
Crankshaft Position Sensor
Engine Oil Level Sensor
Accelerator Pedal Assembly
Oil Pressure Sender
Gauge Assembly
THW
NE
OILH
V2O
Oil Pressure
Switching
Valve Assembly
ECM
VPA
VPA2
POP
THW: Engine Coolant Temperature Sensor Signal
NE: Crankshaft Position Sensor Signal
OILH: Engine Oil Level Sensor Signal
VPA: Accelerator Pedal Position Sensor Signal
VPA2: Accelerator Pedal Position Sensor Signal
POP: Oil Pressure Sender Gauge Signal
V2O: Oil Pressure Switching Valve Operation Signal
15
ON / OFF
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• Oil Pressure Control (Low Pressure)
 When the ECM turns the oil pressure switching valve ON,
sleeve valve and relief valve upward. As a result, opening
pressure of relief valve decreases
ON
Oil Pressure [kPa]
To Engine Parts
Open
Sleeve
Valve
"Rise"
Opening Pressure
of Piston Oil Jet
Engine Speed [rpm]
From Oil Pan
16
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• Oil Pressure Control (High Pressure)
 When the ECM turns the oil pressure switching valve OFF,
relief valve spring is compressed by sleeve valve. As a result,
opening pressure of relief valve increases
OFF
Oil Pressure [kPa]
To Engine Parts
Close
Sleeve
Valve
"Down"
Opening Pressure
of Piston Oil Jet
Engine Speed [rpm]
Relief valve spring is
compressed by sleeve valve
17
From Oil Pan
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• New DTCs
DTC
Detection Item
Trouble Area
• Open or short in oil pressure sender gauge
Engine Oil Pressure
assembly circuit
P0522
Sensor / Switch Low • Oil pressure sender gauge assembly
• ECM
• Short in oil pressure sender gauge assembly
Engine Oil Pressure
circuit
P0523
Sensor / Switch High • Oil pressure sender gauge assembly
• ECM
• Oil pressure sender gauge assembly
Engine Oil Pressure
P0524
• Oil pressure switching valve assembly
Too Low
• ECM
• Open or short in oil pressure switching valve
Engine Oil Pressure
assembly control circuit
P06DA
Control Circuit Open • Oil pressure switching valve assembly
• ECM
• Open or short in oil pressure switching valve
Engine Oil Pressure
assembly control circuit
P06DB
Control Circuit Low • Oil pressure switching valve assembly
• ECM
• Short in oil pressure switching valve assembly
Engine Oil Pressure
control circuit
P06DC
Control Circuit High • Oil pressure switching valve assembly
• ECM
18
Memory
Comes on
stored
Comes on
stored
Comes on
stored
-
stored
-
stored
-
stored
Lubrication System
Oil Pump (Electrically Variable Oil Pressure Type)
• DTC Detection Condition
DTC
DTC Detection Condition
P0522
Oil pressure sender gauge assembly output voltage is 0.04V or less.
(2 trip detection logic)
P0523
Oil pressure sender gauge assembly output voltage is 4.7V or more.
(2 trip detection logic)
P0524
Battery voltage is 11V or more and oil pressure is less than 140 to 270 kPa, and oil pressure
switching valve assembly is turned from on to off and remains off for 1 second. (1 trip
detection logic)
P06DA
Open or short in oil pressure switching valve assembly control circuit.
(1 trip detection logic)
P06DB
Ground short or open in oil pressure switching valve assembly control circuit for 2 seconds
or more. (1 trip detection trip)
P06DC
Battery short in oil pressure switching valve assembly control circuit for 3 seconds or more.
(1 trip detection trip)
19
Lubrication System
Service Point
• Engine Oil Pressure Control Check
 Oil pressure switching valve is forcibly operated by using the
intelligent tester
• Tester Menu: Powertrain > Engine and ECT > Utility >
Engine Oil Pressure Control Check
HINT:
• This check requires the following vehicle conditions.
- Engine is idling and warm it up.
- Vehicle is stopped.
- Acceleration pedal is not depressed.
- Shift position is in Neutral.
• During this check, the engine speed will increase
(Approx. 2,000 rpm) and the oil pressure switching
valve will switch automatically.
- Oil pressure switching valve cannot be switched
manually.
NOTE:
20 Perform this check when DTC P0524 is output.
Lubrication System
Service Point
• Engine Oil Pressure Control Check
21
Lubrication System
Service Point
• Engine Oil Pressure Control Check
 Vehicle operation during this check
Active Test Start
Active Test Finish
High
Oil Pressure
Low
Oil Pressure
Switching
Valve
Engine
Speed
[rpm]
ON
5 Sec.
5 Sec.
5 Sec.
OFF
2,000
Idle
Time
22
Lubrication System
Service Point
• Engine Oil Pressure Control Check
 Reference oil pressure
Item
Specified Condition
Valve Off (High Pressure
Control Mode)
120 to 430 kPa
Valve On (Low Pressure
Control Mode)
80 to 180 kPa
Difference between high
pressure control mode and
low pressure control mode
24.5 kPa or higher
Oil pressure is
measured for 1 sec.
when the valve is
operated, and the
value measured every
0.1 sec. is displayed
for each valve state.
23
Lubrication System
Service Point
• Engine Oil Pressure Control Check (Not Using Tester)
 Standard oil pressure
Engine Condition
Specified Condition
Idling
24.5 kPa or higher
Engine running at 3,200 rpm
150 kPa or higher
 Measurement Results
Engine Condition
Result 1
Result 2
Idling
Normal
Abnormal
Engine running at 3,200 rpm
Abnormal
Abnormal
Oil pressure control
stuck in low oil
pressure control
mode
Clogging in an oil line
(oil strainer, etc.), or a
problem with the oil
pump
HINT:
24
When not using the intelligent tester, it is not possible to determine whether the
system is stuck in high oil pressure control mode.
Cooling System
Overall
• A thermostat with a bypass valve is located on the water inlet
housing to maintain suitable temperature distribution in the cooling
system
Coolant Type
Toyota Super Long
Life Coolant
25
Capacity
w/o Combustion Type
Power Heater
4.9 liters
w/ Combustion Type
Power Heater
5.3 liters
Cooling System
Parts Location
Radiator
Reservoir Tank
Water Pump
Thermostat
Water Inlet
Radiator Assembly
26
Cooling System
Coolant Passages
To Heater Core
To Radiator Assembly
From EGR Cooler
From Heater Core
To EGR Cooler
From Radiator
Reservoir Tank
27
From Radiator Assembly
Cooling System
Coolant Passage
• After warm-up circulation
 A bypass valve is located on the water inlet housing
28
Emission Control System
• Catalyst support control
• When the PM accumulation limit is surpassed, DPF indicator or
message is displayed to prompt the driver to either drive at a
constant speed or take the vehicle to a dealer
Warning Indicator / Warning Message
DPF
Indicator
Light*1
1st Phase
(Illuminate)
When PM regeneration control was not
performed for a certain period.
(Decides the calculated PM accumulation)
DPF
Indicator
Light*1
2nd Phase
(Blinking)
When a predetermined PM accumulation is
reached after 1st phase.
3rd Phase
(Illuminate)
When vehicle keeps driving without PM
regeneration control after 2nd phase.
- DTC P2463 is stored and MIL comes on
(Replacement of the DPF might be required).
MIL
32
Vehicle Conditions
Engine Control System
System Control Table [2/2]
System
Outline
Based on the signals received from the various sensors, the ECM determines
throttle position in accordance with engine condition.
Intake Throttle Control
Fully closes the diesel throttle control valve in order to reduce the vibration
when the engine is stopped.
Cooling Fan Control
Cooling fan operation is controlled by signals from the ECM based on the
coolant temperature, air conditioning condition*1.
Air Conditioning Cut-off
Control*1
By turning the air conditioning compressor on or off in accordance with the
engine condition, drivability is maintained.
Starter Control
(Cranking Hold Function)*2
Once the engine switch is pushed, this control continues to operate the starter
until the engine is started.
Engine Immobiliser
Prohibits fuel injection if an attempt is made to start the engine with an invalid
ignition key.
Oil Maintenance
Management System
When the ECM determines that the engine oil has deteriorated, when the
engine oil level sensor detects that the engine oil level has increased, or when
the running distance exceeds a predetermined value, the engine oil change
reminder indicator light turns on to inform the driver of it.
Brake Override System
When the brake pedal is depressed while driving with the accelerator pedal
depressing, this system may restrain the engine output and support brake
performance
37
*1: Models with air conditioning
*2: Models with entry and start system
Engine Control System
Service Point
• Initialization and Registration
 When ECM and/or other component(s), mentioned below are
replaced, perform the following utility items
Replacement Part
Utility Item
ECM
Injector
Inaccessible
Learning Values
Save / Write
Injector
Compensation
A/F
Sensor
O
O
O
O
O
DPF Deterioration
Record Clear
O
A/F Sensor
Compensation Reset
38
Engine
Assembly
O
Pilot Quantity
Learning Value Reset
Vehicle Mileage Write
DPF
Catalyst
O
O
Engine Control System
Service Point
• Initialization and Registration
 Function of utility items
Utility Item
Learning
Values
Function
Save
This function can record all compensation values, learning values
except supply pump discharge volume variances
Write
Writing saved data from intelligent tester to ECM
Injector Compensation
Inputs injector compensation code manually
NOTE: Function of read compensation code is discontinued
Pilot Quantity Learning
Learns pilot injection quantity variances
Value Reset
DPF Deterioration
Record Clear
Clears catalyst record of DPF thermal deterioration
NOTE: Function of catalyst record transferring (Read catalyst record
and set catalyst record) is discontinued
A/F Sensor
Compensation Reset
Clears air fuel ratio sensor compensation value used for EGR valve
control
Vehicle Mileage Write
If Pilot Quantity Learning Values and DPF Deterioration Record
cannot be saved or written using the intelligent tester, the ECM
estimates the Pilot Quantity Learning Values and DPF Deterioration
Record based on the traveled distance using this function.
39