Handout INST Mesin 2KD

Model Outline

KD Series Engine

Isi

Chassis

Body

Body Electrical

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

Keseluruhan Mesin

Chassis

Body

Body Electrical

2KD-FTV
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

Keseluruhan Mesin

Chassis

Body

Body Electrical

Spesifikasi 2KD-FTV
2KD-FTV
(KIJANG INNOVA)

Item

Slide 4

2L
(KIJANG)

Jumlah Silinder dan

Susunan

4-Cylinder, In-line

Mekanisme Katup

16-Valve DOHC,
Belt & Gear Drive

8-Valve OHC,
Belt Drive

Common-Rail Type

Distributor Type

Sistem Bahan Bakar

Tanpa

2,492 (152.2)

2,446 (149.3)

92.0 x 93.8
(3.62 x 3.69)

92.0 X 92.0
(3.62 X 3.62)

18.5

22.2 : 1

Intercooler
Displacement
cm3 (cu. in.)
Bore x Stroke
mm (in.)
Rasio Kompresi
Max. Output

[EEC]
kW / rpm

75 @ 3,600

61 @ 4,200

Max. Torque

[EEC]
Nm / rpm

200 @ 1,400 ~ 3,200

260 @ 1,600 ~ 2,400 *

160 @ 2,400
*: High Version

Model Outline

KD Series Engine

Keseluruhan Mesin

Chassis

Body

Body Electrical

Fitur
Ruang Mesin
Rotary Solenoid Type
Diesel Throttle

Intercooler (untuk Thailand)

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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

Chassis

KD Series Engine

Kelengkapan Mesin

Body

Body Electrical

Piston
Dengan penggunaan direct injection, ruang bakar
diletakan pada piston

Ni-resist
Cast Iron
Ring Carrier

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Cooling
Channel

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2KD-FTV

Model Outline

Chassis

KD Series Engine

Mekanisme Katup

Body

Body Electrical

Timing Belt
Timing Belt, penggantian setiap 150.000 km

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Oil Pump Drive Gear

Camshaft
Timing
Pulley No. 2

Crankshaft Timing Gear

Supply Pump Drive Gear

Slide 7

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Combustion
Chamber

Slide 6

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Timing
Belt

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Automatic
Belt
Tensioner

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Camshaft
Timing
Pulley No. 1

Vacuum Pump Drive Gear

Idle Gear

Model Outline

Chassis

KD Series Engine

Sistem Pelumasan

Body

Body Electrical

Sistem Pelumasan
Keseluruhan
Pelumasan tipe tekanan penuh dan semua oli
melewati pendingin dan saringan

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Slide 8
Oil Filter

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Oil Cooler

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Model Outline

Chassis

KD Series Engine

Service Point

Body

Body Electrical

Oli mesin dan saringan oli

Jarak Maintenance

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Indonesia
Mesin

Slide 9
Penggantian

Oli
Mesin

Saringa
n Oli

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2KD-FTV

2L

Normal

Setiap 5,000km atau 6 bulan

Parah

Setiap 2,500km atau 3 bulan

Normal

Setiap 10,000km atau 12 bulan

Parah

Setiap 5,000km atau 6 bulan

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Model Outline

KD Series Engine

Chassis

Sistem Intake dan Exhaust

Body

Body Electrical

Intake Shutter Valve

Rotary solenoid type intake shutter valve digunakan
untuk memperbaiki EGR
Kondisi
Mesin

Slide 10

Posisi
Katup

Intake Shutter Valve

Position Sensor

Purpose

Starting

Terbuka
Penuh

Mengurangi
asap diesel

Stop

Tertutup
Penuh

Mengurangi suara
dan getaran

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Air flow

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Intake Shutter Valve

Rotary Solenoid
type Motor

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Hal. 2 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Body

Sistem Intake dan Exhaust

Body Electrical

Intake Shutter Valve

Konstruksi

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Rotary Solenoid
Type Motor

Intake Shutter Valve

Position Sensor

Slide 11

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Steel Layer
Magnet

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Hall IC
Magnet
Magnet

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Model Outline

Chassis

KD Series Engine

Body

Sistem Intake dan Exhaust

Body Electrical

Intake Manifold
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

Chassis

KD Series Engine

Body

Sistem Intake dan Exhaust

Body Electrical

Turbocharger (Hanya 2KD)

Ringan, kompak dan berkemampuan tinggi

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Slide 13

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Waste Gate
Valve

Model Outline

Actuator
for Waste
Gate Valve

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

Umum
NE Signal

Engine
ECU

G Signal
Various
Signals

Slide 14

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Common-rail

Pressure
Switch

Injector

Fuel
Filter
Supply Pump

SCV
Fuel Tank

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EDU
Pressure
Limiter

Fuel
Pressure
Sensor

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Fuel Filter
Warning Light

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Model Outline

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

Fitur
NE Signal
G Signal
Various
Signals

Slide 15

Engine
ECU

EDU

Max. 160MPa

HP3 Type
Fuel
Supply
Pressure
Pump
Sensor

Injector
compensation
Pressure
code
Limiter

Common-rail

Pressure
Switch

Injector

Fuel
Filter
Supply Pump

Replacement
filter
element only

SCV

Detects
filter
clogging

Fuel Tank

Fuel Filter Warning light

Warning Light for fuel filter

clogging and
fuel sedimenter

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Hal. 3 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Common-rail System

Body

Body Electrical

Umum
System ini dapat memberikan tekanan injeksi tinggi di
setiap kecepatan mesin.
NE Signal
Various
Signals

Slide 16

EDU
(Operates injector
at high-speed)

Engine
ECU

G Signal

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Injector
(Injects high-pressure fuel)

SCV
Supply Pump
(Generates high-pressure fuel)

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Fuel Tank

: High-pressure (Max. 160 MPa)

Model Outline

Referensi

Chassis

KD Series Engine

Body

Body Electrical

Umum
Keuntungan common-rail system

Tekanan injeksi, volume dan timing

dikontrol secara elektronik

Slide 17

Atomisasi lebih baik

Menyimpan bahan bakar

tekanan tinggi

Injeksi tekanan tinggi

disemua kecepatan mesin

Suara dan getaran rendah

Chassis

Body

Body Electrical

System Outline
Common-rail Diesel
Constant high pressure
Pressure
Sensor

Conventional Diesel
Instantaneously high pressure

Common-rail

System

SCV

Injector

Supply Pump

Injection
Nozzle

Pump

Injection Volume
Control

ECU (Injector)

Pump (Governor)

Injection Timing
Control

ECU (Injector)

Pump (Timer)

Injection Pressure
Control

Supply Pump (SCV)

According to rotational speed

and injection quantity

Pressurization

Supply Pump

Pump

Distribution

Common-rail

Pump

Injection Pressure

Max. 160 MPa

Approx. 15 MPa

Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Lokasi
Depan

Injector

Fuel Inlet Pipe

Common-rail

Fuel Pressure Sensor

Pressure Limiter

Supply Pump

Model Outline

KD Series Engine

Slide 20

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Chassis

Body

Body Electrical

Supply Pump
Mengirimkan tekanan tinggi ke common-rail
Digerakkan oleh crankshaft

To Common-rail
(Outlet)

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SCV (Suction Control Valve)

Fuel Temp. Sensor

Common-rail System

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Injection Pipe

Slide 19

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Governor

Timer
ECU

Slide 18

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Emisi lebih bersih

KD Series Engine

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High performance dan fuel economy

Common-rail System

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Kontrol mesin yg akurat

Bahan bakar tekanan tinggi

Model Outline

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Pressure
Limiter

Common-rail
(Stores high-pressure fuel)

Fuel Pressure
Sensor

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From Fuel Filter

(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

Chassis

KD Series Engine

Common-rail System

Body

Body Electrical

Supply Pump
Konstruksi

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Eccentric and
Ring Cam

Check
Valve

Slide 21

Delivery
Valve

Plunger

Feed
Pump

Fuel
Temp.
Sensor
SCV (Suction
Control Valve)

Model Outline

Chassis

KD Series Engine

Common-rail System

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Body

Body Electrical

Supply Pump
Konstruksi

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To fuel tank
(return)

Slide 22

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Ring Cam

Plunger

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Eccentric
Cam

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Model Outline

Chassis

KD Series Engine

Common-rail System

Body

Body Electrical

Supply Pump
Aliran Bahan Bakar

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To common-rail

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Slide 23

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Dari Fuel
Tank

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Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Supply Pump
Aliran Bahan Bakar (referensi)

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Slide 24

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Click!
Movie

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Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Supply Pump
Penghisapan dan pemompaan

Plunger A: Hisap
Plunger B: Pompa

Slide 25

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Plunger A: Pompa
Plunger B: Hisap

Check
Valve

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Plunger A

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SCV

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Plunger B

: Dari Feed Pump

: Ke Common-rail

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Hal. 5 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Supply Pump
Penghisapan dan pemompaan

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Slide 26

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Click!
Movie

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Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Supply Pump
Kerja Fuel control (bukaan SCV kecil)

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Fuel
Pumping
Mass

Slide 27

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Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Supply Pump
Kerja Fuel control (bukaan SCV besar)

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Slide 28

Fuel
Pompa
Mass

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Model Outline

Referensi

KD Series Engine

Chassis

Supply Pump
Plunger mebuat
kevacuuman untuk
menghisap bahan bakar
sampai gelembung hilang

Body

Body Electrical

Negative
Pressure

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Slide 29

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Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Supply Pump
Kerja Fuel control (bukaan SCV kecil)

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Slide 30

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Click!
Movie

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Hal. 6 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Common-rail System

Body

Body Electrical

Supply Pump
Kerja Fuel control (bukaan SCV besar)

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Slide 31

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Click!
Movie

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Model Outline

Chassis

KD Series Engine

Common-rail System

Body

Body Electrical

Supply Pump
Bukaan SCV mengontrol volume pemompaan untuk
mengontrol tekanan bahan bakar
[Fuel Pressure Control]
Fuel Pressure
Sensor

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Common-rail
pressure
(Feedback)

SCV

Crankshaft
Position Sensor

Perhitungan
target injection
pressure

Accelerator Pedal
Position Sensor

Engine ECU

Model Outline

KD Series Engine

Common-rail System

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Chassis

Body

Body Electrical

Common-rail
Menyimpan tekanan tinggi (Max. 160 MPa) yang
dikirim oleh supply pump

Slide 33

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Slide 32
Controls
SCV
opening

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Pressure
Limiter

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Fuel
Pressure
Sensor

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Common-rail

Dari
Supply Pump

Model Outline

KD Series Engine

Common-rail System

Ke Injector

Chassis

Ke Fuel Tank

Body

Body Electrical

Common-rail
Fuel pressure sensor
Mendeteksi internal fuel pressure di common-rail

Output characteristic
Output Voltage (V)

Sensor Tip

Slide 34

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2.44
1.0
0
90
190
Common-rail Pressure (MPa)

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KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Injector
Injeksi tekanan tinggi untuk atomisasi yang lebih baik

Kembali ke
Fuel Tank

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4.04

Common-rail
Pressure

Model Outline

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Injector
Compensation
Code
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

Common-rail System

Chassis

Body

Body Electrical

Injector
Konstruksi

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Solenoid Coil
Dari

Kembali ke
Fuel Tank

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Common-rail

Slide 36

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Piston

Nozzle
Spring

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Nozzle
Needle

Model Outline

KD Series Engine

Common-rail System

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Chassis

Body

Body Electrical

Injector
Dikontrol signal dari ECU

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TWV
Small
Orifice

Return

From
Common-rail

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Solenoid
Solenoid

Slide 37

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Large
Orifice

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Click!
Movie

Model Outline

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KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Injector
Pilot injection mengurangi NOx dan suara mesin

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Main
Pilot

Injection
Volume

NOx and
engine noise

Slide 38

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Heat
Release
Value

TDC

Model Outline

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TDC

Conventional
Injection Control

Pilot
Injection Control

KD Series Engine

Common-rail System

Chassis

Body

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Body Electrical

EDU (Electronic Driver Unit)

Mengendalikan injectors saat kecepatan tinggi

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EDU
Battery
DC / DC
Converter

Slide 39

Command
Pulse

IJT
#1-4

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Control
Circuit

High-speed
operation

IJF

Confirmation
Pulse

Engine
ECU

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High
Voltage

Injector

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Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Diagnosis
DTC untuk common-rail system
Area Kerusakan

Slide 40

Detection Condition

Fail-safe

DTC No.

Item Pendeteksian

P0087
(49)

Fuel Rail/System Tekanan terlalu rendah

Open atau short pada fuel pressure sensor

circuit Fuel pressure sensor Engine ECU

Area Kerusakan

P0088
(78)

Fuel Rail/System Tekanan

terlalu tinggi

Short pada supply pump (SCV) circuit Supply

pump (SCV) Engine ECU

P0093
(78)

Terdeteksi Bahan Bakar

bocor, bocor besar

Jalur bahan bakar high pressure

Open pada short pada EDU circuit
Open atau short pada injector circuit
Supply pump Common-rail Injectors EDU
Engine ECU

P0190
(49)

Fuel Rail Pressure Sensor

Circuit Malfunction

P0192
(49)

Fuel Rail Pressure Sensor

Circuit Low Input

P0193
(49)

Fuel Rail Pressure Sensor

Circuit High Input

Open atau short pada fuel pressure sensor

circuit
Fuel pressure sensor
Engine ECU

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Hal. 8 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Diagnosis
DTC untuk common-rail system
Trouble Area

Slide 41

Kondisi Pendeteksian

Fail-safe

Kondisi Pendeteksian

Item Pendeteksian

P0087
(49)

Fuel Rail/System Pressure Terlalu rendah

Fuel pressure sensor output voltage nilainya

tidak berubah

P0088
(78)

Fuel Rail/System Pressure Terlalu tinggi

Tekanan melebihi 200 MPa (2039 kgf/cm2)

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P0093
(78)

Terdeteksi kebocoran pada

sistem Bahan Bakar Bocor
besar

Perbedaan tekanan common-rail sebelum dan

setelah injeksi bahan bakar berbeda jauh dari
yang sudah di hitung ECU sebelum dan sesudah
injeksi

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P0190
(49)

Fuel Rail Pressure Sensor

Circuit Malfunction

Fuel pressure sensor output voltage 0.55V atau

kurang, atau 4.9V atau lebih selama 0.5 sec.

P0192
(49)

Fuel Rail Pressure Sensor

Circuit Low Input

Fuel pressure sensor output voltage 0.55V atau

kurang selama 0.5 sec.

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P0193
(49)

Fuel Rail Pressure Sensor

Circuit High Input

Fuel pressure sensor output voltage 4.9V atau

lebih selama 0.5 sec.

Model Outline

KD Series Engine

Common-rail System

Chassis

Body

Body Electrical

Diagnosis
DTC untuk common-rail system
Trouble Area

DTC No.

Item Pendeteksian

P0087
(49)

Fuel Rail/System Pressure Terlalu rendah

P0088
(78)

Fuel Rail/System Pressure Terlalu tinggi

P0093
(78)

Terdeteksi kebocoran sistem

Bahan Bakar Bocor besar

P0190
(49)

Fuel Rail Pressure Sensor

Circuit Malfunction

P0192
(49)

Fuel Rail Pressure Sensor

Circuit Low Input

P0193
(49)

Fuel Rail Pressure Sensor

Circuit High Input

Model Outline

KD Series Engine

Common-rail System

Detection Condition

Fail-safe

Fail-safe

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Membatasi power mesin

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Chassis

Body

Body Electrical

Detection Condition

Fail-safe

Area Kerusakan

P0200
(97)

Injector Circuit / Open

Open atau short pada EDU circuit

EDU
Injector
Engine ECU

P0627
(78)

Fuel Pump Control Circuit

/ Open

Open atau short pada (SCV) circuit

SCV
Engine ECU

P1229
(78)

Fuel Pump System

Short pada supply pump (SCV) circuit

Supply pump (SCV)
Engine ECU

P1601
(89)

Injector Correction
Circuit Malfunction
(EEPROM)

Injector compensation code

Engine ECU

Slide 43

Model Outline

KD Series Engine

Chassis

Body

Trouble Area

Body Electrical

Kondisi Pendeteksian

Fail-safe

Injector Circuit / Open

Open atau short pada EDU atau injector circuit.

Setelah mesin hidup, tak ada injection
confirmation (INJF) signal dari EDU ke engine
ECU, walau engine ECU mengirim injection
command (IJT) signal ke EDU

Fuel Pump Control Circuit /

Open

Open atau short pada suction control valve

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
(78)

Injector Correction Circuit

Malfunction (EEPROM)

Injector compensation code tidak ter-register

P1601
(89)

Injector Circuit / Open

Open atau short pada EDU atau injector circuit.

Setelah mesin hidup, tak ada injection
confirmation (INJF) signal dari EDU ke engine
ECU, walau engine ECU mengirim injection
command (IJT) signal ke EDU

P0200
(97)

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis
DTC untuk common-rail system
Trouble Area

DTC No.

Detection Item

P0200
(97)

Injector Circuit / Open

P0627
(78)

Fuel Pump Control Circuit

/ Open

P1229
(78)

Fuel Pump System

P1601
(89)

Injector Correction
Circuit Malfunction
(EEPROM)

Detection Condition

Fail-safe

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1 trip detection logic untuk semua DTC

Common-rail System

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Diagnosis
DTC untuk common-rail system

DTC No.

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Membatasi power mesin selama 1 min.,

kemudian mematikan mesin

Item Pendeteksian

Common-rail System

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Area Kerusakan

DTC No.

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Membatasi power mesin

Diagnosis
DTC untuk common-rail system

Slide 44

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DTC No.

1 trip detection logic untuk semua DTC

Slide 42

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Fail-safe

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Slide 45
Membatasi Power Mesin

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Hal. 9 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Common-rail System

Slide 46

Chassis

Body

Body Electrical

________________________________________

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)

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Model Outline

Chassis

KD Series Engine

Service Point

Body

Body Electrical

________________________________________

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

________________________________________
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Inisialisasi hanya dibutuhkan jika mesin tak bisa hidup setelah penggantian

Model Outline

Chassis

KD Series Engine

Service Point

Body

Body Electrical

________________________________________

Supply Pump Initialization and Calibration

Prosedur
Setelah
Penggantian,

Engine
stop

________________________________________

Inisialisasi
CG

TC
for 3 min.
DLC3

Slide 48

IG Turn

IG ON

Short
Start engine

Kalibrasi

________________________________________
Idling for 1 min.

KD Series Engine

________________________________________

Start engine

Warm-up

Model Outline

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IG OFF

Learning

THW > 60 C
THF > 20 C

Service Point

Resetting

Chassis

Body

________________________________________

IG OFF

Body Electrical

________________________________________

Common-rail Replacement
Common-rail tak boleh di bongkar
(Penggantian Assembly)

________________________________________
________________________________________

Jangan

Slide 49

Dibuka !

Fuel Pressure
Sensor

________________________________________
Pressure
Limiter

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Jika injector atau ECU mesin diganti, perlu
memprogram ulang nilai injector compensation
Ganti
Injektor

Nomor
Injektor baru
Program ulang
data

Slide 50

ECU mesin

Ganti ECU
mesin

Masukan
nomor

________________________________________
________________________________________
________________________________________
________________________________________
________________________________________

Semua nomor
injektor

________________________________________

Hal. 10 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Service Point

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________

Select

Slide 53

Powertrain

Engine and ECT

Utility

Injector Compensation

________________________________________
________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________
________________________________________

Slide 54

________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

Slide 55

Body Electrical

________________________________________
________________________________________
________________________________________

Read
Compensation
Code

________________________________________
________________________________________
________________________________________

Hal. 11 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________
________________________________________

Slide 56

________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

Slide 57

________________________________________
________________________________________
________________________________________

Select
cylinder No.

________________________________________
________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________
________________________________________

Slide 58

________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________
________________________________________

Slide 59

________________________________________
________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________
________________________________________

Slide 62

________________________________________
________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________

Selesai
menyimpan No.1
cylinders injector
compensation code

Slide 63

________________________________________
________________________________________
________________________________________

Baca dan simpan

injector
compensation
codes yang lain

Selesai

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Catat injector compensation codes
(sebelum mengganti engine ECU)

________________________________________
________________________________________
________________________________________

Slide 64

________________________________________
________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

Body Electrical

________________________________________
________________________________________
________________________________________

Slide 65
Set the
Compensation
Codes

Click!

________________________________________
________________________________________
________________________________________

Hal. 13 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________

Select

Slide 66

Powertrain

Engine and ECT

Utility

Injector Compensation

________________________________________
________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________
________________________________________

Slide 67

________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

Slide 68

________________________________________
________________________________________
________________________________________

Set
Compensation
Code

________________________________________
________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________
________________________________________

Slide 69

________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

Slide 70

Body Electrical

________________________________________
________________________________________
________________________________________

Select
cylinder No.

________________________________________
________________________________________
________________________________________

Hal. 14 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________
________________________________________

Slide 71

________________________________________
Next

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________
________________________________________

Slide 72
Input

Open

(Input manually)

(Input saved data)

________________________________________
________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)
Input
Nomor

________________________________________
________________________________________

Slide 73

________________________________________
30

________________________________________

Input

(Input manually)

________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)
Input
Nomor

Slide 74

________________________________________
________________________________________

________________________________________
30

OK

________________________________________

01BBC0DFED00E70D000000000000A2

________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

Body Electrical

________________________________________
________________________________________
________________________________________

Slide 75
Open

________________________________________
________________________________________
________________________________________

Hal. 15 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________
________________________________________

Slide 76

________________________________________
________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________

Periksa bahwa
compensation code
benar

Slide 77

________________________________________

Next

________________________________________
________________________________________
________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________
________________________________________
________________________________________

Slide 78

________________________________________
________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

________________________________________

Selesai setting
No.1 cylinders
injector
compensation code

Slide 79

________________________________________
________________________________________
________________________________________

Set injector
compensation
codes yang
lainnya

Selesai

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Program ulang Injector Compensation Code

Registrasi injector compensation codes
(setelah penggantian)

Slide 80

Body Electrical

________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________

Hal. 16 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Service Point

Body

Body Electrical

Penggantian parts baru

Parts yang tidak boleh dipakai ulang (huruf merah)
Nozzle
Holder Seal

Injector

________________________________________
________________________________________

Back-up Ring
O-ring

Slide 81

________________________________________

Head Cover

Nozzle Seat

________________________________________

Gasket
O-ring

________________________________________

Leakage Pipe

Supply Pump

________________________________________
Model Outline

Chassis

KD Series Engine

Service Point

Body

Body Electrical

Penggantian pipa baru

Ganti dengan pipa baru jika mengganti komponenkomponen berikut
Injection
Pipes

Slide 82

Komponen yang
diganti

Injection
Pipes

Supply Pump
Common-rail
Cylinder Block
Cylinder Head
Cylinder Gasket
Gear Case

Fuel Inlet
Pipe

________________________________________
________________________________________
Fuel Inlet Pipe

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

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)
[90405-06167]

Oles dengan air sabun pada

sambungan, periksa ada
nya gelembung

________________________________________
________________________________________
________________________________________
________________________________________

Nozzle
Leakage
Pipe

Slide 83

________________________________________
250 kPa

________________________________________

Lepas

Check Valve
(Part No. 23122-27010)

SST (09992-00242)

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Periksa kebocoran (Sistem Bahan Bakar)

________________________________________
________________________________________
________________________________________

1, Mesin berhenti
Tak ada kebocoran

________________________________________

2, Start mesin

Slide 84

________________________________________
________________________________________

Pipa yang
diganti

Injector
Common-rail
Cylinder Head

________________________________________

Tak ada kebocoran

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

Service Point

Chassis

Body

Body Electrical

Power Balance Check

Gunakan Intelligent Tester II (Active Test) untuk
pemeriksaan power balance

Slide 85

Active Test
Injector Cut
Injector Cut
Injector Cut
Injector Cut

________________________________________
________________________________________
________________________________________

#1
#2
#3
#4
Tegangan
Tinggi

________________________________________
________________________________________

Jangan melepas
konektor injektor

________________________________________

Hal. 17 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

Saringan Bahan Bakar

Hanya mengganti element saringan
Priming
Pump

________________________________________

Fuel Filter
Warning Switch

________________________________________

Ke Supply Pump

Dari Fuel Tank

Slide 86

________________________________________

Fastener Nut

________________________________________

Filter Housing
(Plastic)

________________________________________

Filter Element

________________________________________

Drain Cock

Model Outline

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

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

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

Fuel Filter Warning

Tersumbat nya Saringan Bahan Bakar dideteksi oleh
Fuel Filter Warning Switch
Fuel Filter
Warning Switch

Fuel Filter
Warning Light

Combination Meter

________________________________________

Fuel Filter

________________________________________

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

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

Fuel Filter Warning

System Diagram

Fuel Filter
Warning Switch

________________________________________

Meter
ECU
Fuel Filter
Warning Light

Ke Supply Pump

Filter Element

Model Outline

Chassis

KD Series Engine

Sistem Bahan Bakar

________________________________________

Body

Body Electrical

Fuel Filter Warning

Fuel filter warning switch akan OFF saat tekanan
outlet filter menurun

Slide 90

________________________________________
________________________________________

Fuel Sedimenter Level Warning Switch

Fuel Filter
Warning
Switch

________________________________________
________________________________________

Combination Meter
Vehicle Speed
Sensor

Fuel Filter

________________________________________
________________________________________

Tersumbat

Slide 89

________________________________________
________________________________________

Slide 88

Model Outline

________________________________________

ON Meter
ECU

Fuel Filter
Warning
Switch

________________________________________
________________________________________

OFF Meter
ECU

________________________________________

Diaphragm
Ke Supply Pump

Filter Element

Normal Fuel Filter

(Switch: ON)

Ke Supply Pump

Negative
Pressure

Fuel Filter Tersumbat

(Switch: OFF)

________________________________________
________________________________________
________________________________________

Hal. 18 dari 22

Handout INST Mesin 2KD

Model Outline

Chassis

KD Series Engine

Sistem Bahan Bakar

Body

Body Electrical

Fuel Filter Warning

Kondisi warning light untuk fuel filter / fuel sedimenter

Warning
Method

Warning

Slide 91

________________________________________
________________________________________

Prioritas

________________________________________

________________________________________

________________________________________

Sedimenter
Warning
Berkedip
Fuel Filter
Warning
ON

________________________________________
Model Outline

KD Series Engine

Sistem Bahan Bakar

Chassis

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

Fuel Filter Warning

Buka elemen Saringan Bahan Bakar

________________________________________

Inlet hose

________________________________________

Fuel
Level

Slide 94

________________________________________

________________________________________
Drain
Cock

Lepas
konektor
dan hose

Model Outline

KD Series Engine

Service Point

Keluarkan bahan bakar untuk

menurunkan permukaan nya

Chassis

Body

Body Electrical

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

Service Point

Chassis

Body

Body Electrical

Fuel Filter Warning

Buka/Pasang Saringan Bahan Bakar element
Pasang Saringan
Bahan Bakar

Element

Slide 96

________________________________________
________________________________________
________________________________________
________________________________________

Rumah

Element

Pasang O-ring baru

Buka tutupnya, lepas
elemen

Model Outline

KD Series Engine

Service Point

________________________________________
________________________________________

Chassis

Body

Body Electrical

Fuel Filter Warning

Pasang Saringan Bahan Bakar

________________________________________
________________________________________

Tanda

Tanda

Slide 97

________________________________________
________________________________________

Elemen
baru

________________________________________

Pasang elemen baru dan

pasang tutup filter
(luruskan tanda)

Model Outline

KD Series Engine

Service Point

Kencangkan pengunci sampai

tanda nya lurus

Chassis

Body

Body Electrical

Fuel Filter Warning

Pasang Saringan Bahan Bakar

________________________________________
________________________________________
________________________________________
________________________________________

Inlet Hose

Slide 98

________________________________________
Kencangkan tutup
bahan bakar
Hubungkan

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Fuel Filter Warning

Pasang Saringan Bahan Bakar / Reset warning light
Reset warning light

________________________________________
________________________________________
________________________________________

Slide 99

dalam
3 - 60 detik

3 detik.

IG ON

________________________________________
OFF

Pasang

________________________________________
________________________________________

Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Fuel Filter Warning

Pasang Saringan Bahan Bakar / Reset warning light
Keluarkan udara pada
Sistem Bahan Bakar

Slide
100

________________________________________
________________________________________
________________________________________

pompa

Selesai

________________________________________
________________________________________
________________________________________

Hal. 20 dari 22

Handout INST Mesin 2KD

Model Outline

KD Series Engine

Sistem Pengisian

Chassis

Body

Body Electrical

Alternator Pulley
Untuk menyerap fluktuasi mesin, digunakan oneway clutch pada pulleyalternator

________________________________________
________________________________________
________________________________________

Slide
101

________________________________________
Spring

________________________________________

Sprag

________________________________________
Model Outline

KD Series Engine

Sistem Pengisian

Chassis

Body

Body Electrical

Alternator Pulley
Mekanisme penyerapan fluktuasi mesin
One-way
Clutch
Locked

________________________________________

Crankshaft Pulley
Speed

________________________________________

One-way
Clutch
Free

Slide
102

________________________________________
Pulley Speed (rpm)

Alternator
Pulley Speed

Model Outline

KD Series Engine

Service Point

Engine
Fluctuation

Chassis

Body

________________________________________
________________________________________

Time

Body Electrical

Alternator Pulley
Gunakan SST, saat membuka atau memasang
alternator pulley
SST (09820-63020):
2 parts

Slide
103

________________________________________

________________________________________
________________________________________
________________________________________
________________________________________

Buka

________________________________________
________________________________________
Model Outline

KD Series Engine

Service Point

Chassis

Body

Body Electrical

Alternator Pulley
Alternator pulley cap hanya sekali pakai

________________________________________
________________________________________
________________________________________

Slide
104
Alternator Pulley Cap
(Non-reusable Part)

________________________________________
________________________________________
________________________________________

Model Outline

KD Series Engine

Chassis

Sistem Serpentine Belt Drive

Body

Body Electrical

Serpentine Belt Drive

Single V-ribbed belt
Air Conditioner
Compressor Pulley

Idler Pulley

________________________________________
________________________________________

Water Pump Pulley

Idler Pulley

Slide
105

Alternator Pulley
with Shock
Absorbing Function

Crankshaft Pulley

________________________________________
________________________________________

Idler Pulley for

Automatic Tensioner
- jarak penggantian Indonesia
2KD-FTV baru

2L

Periksa pada 100,000km pertama,

periksa setiap 20,000km

Periksa setiap 20,000 km atau 24 bulan

Ganti setiap 40,000km atau 48 bulan

________________________________________
________________________________________

Hal. 21 dari 22

Handout INST Mesin 2KD

Model Outline

Referensi

KD Series Engine

Chassis

Body

Body Electrical

Intake Shutter Valve

Intake shutter valve position sensor

________________________________________

Magnet
Output Voltage (V)

Hall IC

Slide
106

VC

Engine
ECU

VLU

E2

________________________________________
________________________________________

5
3.51

________________________________________

1
0.71
0
0
20
(Full Close)

Intake Shutter
Valve Position
Sensor

70
(Full Open)

100

Intake Shutter Valve

Opening Angle ()

________________________________________
________________________________________

Model Outline

Referensi

KD Series Engine

Chassis

Body

Body Electrical

Accelerator Pedal
Non-contact type accelerator pedal position sensor
Accelerator Pedal
Position Sensor

________________________________________
________________________________________
________________________________________

Slide
107

________________________________________
________________________________________
________________________________________
Model Outline

Referensi

KD Series Engine

Chassis

Body

Body Electrical

Accelerator Pedal
Using magnet dan hall IC

________________________________________
________________________________________

VCP1
Magnets

________________________________________

Output Voltage (V)

VPA1

Slide
108

EP1
VCP2
Hall
IC

VPA2
EP2

Accelerator
Pedal Position
Sensor

5
VPA2

0
Full Close

Engine
ECU

________________________________________
VPA1
Full Open

Accelerator Pedal Depressed Angle

________________________________________
________________________________________

Hal. 22 dari 22