Professional Documents
Culture Documents
REPORT
TOYOTA HILUX ROGUE
ENGINE MECHANICALS
CYLINDER BLOCK
CONNECTING ROAD
5-20
PISTON AND RINGS
CRANKSHAFT
FLYWHEEL
ENGINE VALVE
INTAKE AND EXHAUST VALVE
AIR FILTER
OIL FILTER
SPARK PLUG
CONCLUSION 20
REFERRENCE 20
INTRODUCTION:
The Toyota Hilux (Japanese: トヨタ・ハイラックス, Hepburn: Toyota
Hairakkusu); stylized as HiLux and historically as Hi-Lux, is a series of pickup
trucks produced and marketed by the Japanese automobile manufacturer
Toyota. The majority of these vehicles are sold as pickup truck or cab chassis
variants, although they could be configured in a variety of body styles.
The pickup truck was sold with the HiLux name in most markets, but in North
America, the Hilux name was retired in 1976 in favor of Truck, Pickup Truck, or
Compact Truck. In North America, the popular option package, the SR5 (Sport
Runabout 5-Speed), was colloquially used as a model name for the truck, even
though the option package was also used on other Toyota models, like the
1972 to 1979 Corolla. In 1984, the Trekker, the wagon version of the Hilux, was
renamed the 4Runner in Venezuela, Australia and North America, and the
Hilux Surf in Japan. In 1992, Toyota introduced a newer pickup model, the mid-
size T100 in North America, necessitating distinct names for each vehicle other
than Truck and Pickup Truck. Since 1995, the 4Runner is a standalone SUV, and
the more recent models of the Hilux are separate in appearance from the
Tacoma.
In June 2020, Toyota unveiled the second facelift of the AN120/130 series Hilux
for Asia, Europe and South America. The second facelift model received revised
front and rear with LED headlamps and tail-lamps and front LED indicators, a
first for the Hilux, and redesigned 18-inch alloy wheels. For some Southeast
Asian markets, the Hilux is equipped with Toyota Safety Sense. This facelift of
the Hilux was introduced in Japan in August 2020 and is offered in base X and Z
trim levels. The power and torque figures for 2.8-litre 1GD-FTV engine has
been upgraded to 204 PS (150 kW; 201 hp) and 500 N⋅m (369 lbf⋅ft) (in
automatic transmission).
The facelift model GR Sport version was released in Thailand on 25 August
2021,[78][79] in Japan on 8 October 2021,[80] in the Philippines on 23 October
2021,[81] and in Europe on 4 January 2022.[82] The model will also be
released in South Africa in May 2022, with the 1GD-FTV engine is further
upgraded to produce 224 PS (165 kW; 221 hp) and 550 N⋅m (406 lbf⋅ft).
While Toyota’s updated 2021 HiLux, LandCruiser Prado and Fortuner still carry
over the same 2.8-litre turbo-diesel engine as the respective outgoing models,
there have been a lot of mechanical changes for the new models. And Toyota
Australia is adamant the worst of its diesel particulate filter dramas are behind
them. This new iteration engine has more power and torque, and claims to be
more efficient at the same time.
Still called the 1GD-FTV, this new engine now makes 150kW at 3400rpm and
500Nm at 1600-2800rpm when running through the automatic transmission.
With a manual transmission, the torque output is capped at 420Nm at 1400-
3400rpm.
This is an improvement over the outgoing engine, which made 130kW at
3400rpm and 450Nm at 1600-2400rpm with an automatic transmission, or
420Nm at 1400-2600rpm with a manual transmission. While peak torque has
improved only for the automatic transmission, the torque curve is both wider
and flatter for both variants.
A new variable nozzle ball-bearing turbocharger, which is larger, is mainly
responsible for the gains in power and torque. This new turbo hangs off a
redesigned exhaust manifold. The common-rail fuel injection system has also
been updated, with changes to the injector flow rate.
The new cylinder head has a redesigned water jacket to improve cooling, and
the cylinder block has been made more rigid to accommodate the higher
engine performance. Pistons and piston rings have been redesigned, and there
is a new cooling fan and coupling.
There’s also a new head gasket for this more powerful engine, presumably
done to handle the increased amount of boost that this engine develops.
Toyota says the diesel particulate filter system (DPF) for this new engine has
also been reworked, with software and hardware changes implemented on the
facelifted model.
The design of the air filtration system in the new HiLux has been left
untouched. While Toyota concedes that "minute dust particles in fact can pass
through the filter" in extremely dusty conditions, Mr Hanley said "this is not
known to cause any engine damage, based upon the very thorough evaluations
and assessments we have done… in quite incredible driving conditions."
While the manual transmission has been left unchanged, the automatic
transmission has been recalibrated for faster and more frequent torque
converter lockup, which allows the driveline to run cooler.
These changes, along with the improved cooling capability of the engine, has
been an instrumental part of increasing the towing capacity to 3.5 tonnes for
all HiLux 4x4 models. The Toyota Fortuner now has a towing capacity of
3100kg and diesel-powered 4x2 HiLux variants can tow 2800kg.
PICTURE OF THE ENGINE:
ENGINE MECHANICALS:
-CYLINDER BLOCK
The engine block - also known as a cylinder block - contains all of the major
components that make up the bottom end of a motor. This is where the
crankshaft spins, and the pistons move up and down in the cylinder bores,
fired by the fuel combusting. On some engine designs, it also holds the
camshaft.
Usually made from an aluminum alloy on modern cars, on older vehicles and
trucks it was commonly cast iron. Its metal construction gives it strength and
the ability to transmit heat from the combustion processes to the integral
cooling system in an efficient manner. Aluminum block typically have an iron
sleeve pressed into them for the piston bores, or a special hard plating applied
to the bores after machining.
The block was originally just a block of metal holding the cylinder bores, the
water cooling jacket, oil passages, and the crankcase. This water jacket, as it’s
sometimes known, is an empty system of passages, circulating coolant in the
engine block. The water jacket surrounds the engine’s cylinders, of which there
are usually four, six or eight and which contain the pistons.
When the cylinder head is in place secured to the top of the engine block, the
pistons move up and down within the cylinders and turn the crankshaft, which
ultimately drives the wheels. The oil pan sits at the base of the engine block,
providing a reservoir of oil for the oil pump to pull from, and supply the oil
passages and moving parts.
-CONNECTING ROAD
A connecting rod is the part of a piston engine that connects
the piston to the crankshaft. Together with the crank, the
connecting rod converts the reciprocating motion of the
piston into the rotation of the crankshaft.
The connecting rod is required to transmit the compressive
and tensile forces from the piston. In its most common form,
in an internal combustion engine, it allows pivoting on the
piston end and rotation on the shaft end.
The predecessor to the connecting rod is a mechanical
linkage used by water mills to convert the rotating motion of
the water wheel into reciprocating motion. The most
common usage of connecting rods is in internal combustion
engines or on steam engines.
A piston ring must provide a predictable and positive radial fit between the cylinder wall and
the running surface of the piston ring for an efficient seal. The radial fit is achieved by the
inherent pressure of the piston ring. The piston ring must also maintain a seal on the piston
ring lands.
In addition to inherent pressure, a piston ring seals the combustion chamber through applied
pressure. Applied pressure is pressure applied from combustion gases to the piston ring,
causing it to expand. Some piston rings have a chamfered edge opposite the running surface.
This chamfered edge causes the piston ring to twist when not affected by combustion gas
pressures.
Another piston ring design consideration is cylinder wall contact pressure. This pressure is
usually dependent on the elasticity of the piston ring material, free piston ring gap, and
exposure to combustion gases. All piston rings used by Briggs & Stratton engines are made
of cast iron. Cast iron easily conforms to the cylinder wall. In addition, cast iron is easily
coated with other materials to enhance its durability. Care must be exercised when handling
piston rings, as cast iron is easily distorted. Piston rings commonly used on small engines
include the compression ring, wiper ring, and oil ring.
Compression Ring
The compression ring is the top or closest ring to combustion gases and is exposed to the
greatest amount of chemical corrosion and the highest operating temperature. The
compression ring transfers 70% of the combustion chamber heat from the piston to the
cylinder wall. Most Briggs & Stratton engines use either taper-faced or barrel-faced
compression rings. A taper faced compression ring is a piston ring that has approximately a
1° taper angle on the running surface. This taper provides a mild wiping action to prevent any
excess oil from reaching the combustion chamber.
A barrel faced compression ring is a piston ring that has a curved running surface to provide
consistent lubrication of the piston ring and cylinder wall. This also provides a wedge effect
to optimize oil distribution throughout the full stroke of the piston. In addition, the curved
running surface reduced the possibility of an oil film breakdown due to excess pressure at the
ring edge or excessive piston tilt during operation.
Wiper Ring
The wiper ring, sometimes called the scraper ring, Napier ring, or back-up compression ring,
is the next ring away from the cylinder head on the piston. The wiper ring provides a
consistent thickness of oil film to lubricate the running surface of the compression ring. Most
wiper rings in Briggs & Stratton engines have a taper angle face. The tapered angle is
positioned toward the oil reservoir and provides a wiping action as the piston moves toward
the crankshaft.
The taper angle provides contact that routes excess oil on the cylinder wall to the oil ring for
return to the oil reservoir. A wiper ring incorrectly installed with the tapered angle closest to
the compression ring results in excessive oil consumption. This is caused by the wiper ring
wiping excess oil toward the combustion chamber.
Oil Ring
An oil ring includes two thin rails or running surfaces. Holes or slots cut into the radial center
of the ring allow the flow of excess oil back to the oil reservoir. Oil rings are commonly one
piece, incorporating all of these features. Some on-piece oil rings utilize a spring expander to
apply additional radial pressure to the piston ring. This increases the unit (measured amount
of force and running surface size) pressure applied at the cylinder wall.
The oil ring has the highest inherent pressure of the three rings on the piston. Some Briggs &
Stratton engines use a tree-piece oil ring consisting of two rails and an expander. The oil
rings are located on each side of the expander. The expander usually contains multiple slots
or windows to return oil to the piston ring groove. The oil ring uses inherent piston ring
pressure, expander pressure, and the high unit pressure provided by the small running surface
of the thin rails.
The piston acts as the movable end of the combustion chamber and must withstand pressure
fluctuations, thermal stress, and mechanical load. Piston material and design contribute to the
overall durability and performance of an engine. Most pistons are made from die- or gravity-
cast aluminum alloy. Cast aluminum alloy is lightweight and has good structural integrity and
low manufacturing costs. The light weight of aluminum reduces the overall mass and force
necessary to initiate and maintain acceleration of the piston. This allows the piston to utilize
more of the force produced by combustion to power the application. Piston designs are based
on benefits and compromises for optimum overall engine performance.
-CRANKSHAFT
An engine crankshaft runs inside the bottom end of a car's motor and
converts the vertical movement of the pistons into horizontal rotational
movement, which ultimately drives the wheels via the gearbox.
-FLYWHEEL
Why Is It Important?
Think of it this way: If you were turning a rotating shaft with a crank
handle, you’d likely be able to apply more muscle at some points
during a full revolution than at others. But if there was a heavy
flywheel at the end of the shaft, the rotating momentum of the
flywheel would help you rotate the shaft at a more consistent speed.
Its momentum would also keep the shaft turning even after you let
go of the handle.
-ENGINE VALVE
Engine valves are mechanical components used in internal combustion engines to allow or
restrict the flow of fluid or gas to and from the combustion chambers or cylinders during
engine operation. Functionally, they perform similarly to many other types of valves in that
they block or pass flow, however, they are a purely mechanical device that interfaces with
other engine components such as rocker arms in order to open and close in the correct
sequence and with the correct timing.
Engine valves are located in the cylinder head. The main function of the engine
valves is to let air in and out of the cylinders. That air is used to help ignite the
fuel which will drive the pistons up and down.
There are two types of engine valves; intake and exhaust valves.
-AIR FILTER
-SPARK PLUG
-Fuel injector
The fuel injector is an electronically controlled valve that is
supplied with pressurized fuel by the fuel pump and when
energized atomizes the fuel into a fine mist so that it can
burn easily in the vehicle's engine. The engine uses a long
body injector to optimise fuel spray shape and minimize fuel
atomization to realize rapid combustion. Fuel injectors are
responsible for spraying a mist of fuel into the engine. The
finer and more controlled the spray, the better the fuel
economy.
CONCLUSION
Toyota Hilux is a nice looking pickup and with all that
specification and futuristics modern system powered by
engine 1GD 2.8-litre 4 cylinders turbo diesel engine is
the best car to choose in this category so far.
REFFERENCE
https://toyota.com.my/vehicles/pickup/hilux?
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QAvD_BwE
https://haynes.com/en-gb/