2.5L Diesel Engine System Overview

Model Outline Mesin 2KD-FTV Chassis Body Body Electrical
Isi
Klik pada Sub Seksi
Keseluruhan Mesin
Kelengkapan Mesin
Mekanisme Katup
Sistem Pelumasan
Sistem Intake dan Exhaust
Common-rail System
Sistem Bahan Bakar
Sistem Pengisian
Sistem Serpentine Belt Drive
Keseluruhan Mesin
2KD-FTV
– Mesin Diesel TOYOTA D-4D, 2.5 liter, in-line
4-cylinder, 16 valve DOHC dengan turbocharger
Lokasi Nomor mesin
2KD-FTV
Keseluruhan Mesin
Spesifikasi 2KD-FTV
2KD-FTV 2L
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
Intercooler Tanpa 
Displacement
2,492 (152.2) 2,446 (149.3)
cm3 (cu. in.)
Bore x Stroke 92.0 x 93.8 92.0 X 92.0
mm (in.) (3.62 x 3.69) (3.62 X 3.62)
Rasio Kompresi 18.5 22.2 : 1
Max. Output [EEC]
75 @ 3,600 61 @ 4,200
kW / rpm
Max. Torque [EEC] 200 @ 1,400 ~ 3,200
160 @ 2,400
N·m / rpm 260 @ 1,600 ~ 2,400 *
*: High Version
Keseluruhan Mesin
Fitur
– Ruang Mesin Rotary Solenoid Type
Diesel Throttle
•SLLC Fuel Filter

•Pressurized •Fuel filter warning (Sumbatan)
reservoir •Tipe penggantian elemen saja
Kelengkapan Mesin
Piston
– Dengan penggunaan direct injection, ruang bakar
diletakan pada piston
Combustion
Chamber
Ni-resist
Cast Iron
Ring Carrier
Cooling
Channel
2KD-FTV
Mekanisme Katup
Timing Belt
– Timing Belt, penggantian setiap 150.000 km
Oil Pump Drive Gear
Camshaft
Timing Crankshaft Timing Gear
Pulley No. 2
Supply Pump Drive Gear
Timing
Belt
Automatic
Belt
Tensioner
Camshaft
Timing
Pulley No. 1 Vacuum Pump Drive Gear
Idle Gear
Sistem Pelumasan
Sistem Pelumasan
– Keseluruhan
• Pelumasan tipe tekanan penuh dan semua oli
melewati pendingin dan saringan
Oil Filter
Oil Cooler
Service Point
Oli mesin dan saringan oli
– Jarak Maintenance
Indonesia
Mesin 2KD-FTV 2L
Normal Setiap 5,000km atau 6 bulan 

Penggantian
Oli Mesin
Abnormal Setiap 2,500km atau 3 bulan 
Normal Setiap 10,000km atau 12 bulan

Saringan Oli
Abnormal Setiap 5,000km atau 6 bulan
Intake Shutter Valve
– Rotary solenoid type intake shutter valve digunakan
untuk memperbaiki EGR
Kondisi Posisi Intake Shutter Valve

Purpose Position Sensor
Mesin Katup
Terbuka Mengurangi
Starting Penuh asap diesel
Tertutup Mengurangi suara
Stop Penuh dan getaran
Air flow
Rotary Solenoid
type Motor
– Konstruksi
Rotary Solenoid
Intake Shutter Valve Type Motor
Position Sensor
Steel Layer
Magnet
Hall IC
Magnet
Magnet
Intake Manifold
• 2 intake port dengan bentuk berbeda dari intake
manifold ke cylinder head
 Untuk mengoptimalkan “swirl” (putaran)
Turbocharger (Hanya 2KD)
– Ringan, kompak dan berkemampuan tinggi
Waste Gate Actuator

Valve for Waste
Gate Valve
Sistem Bahan Bakar
Umum
NE Signal
Engine
G Signal EDU
ECU
Various
Pressure
Signals Limiter
Fuel Common-rail
Pressure
Sensor
Pressure
Switch Injector
Fuel
Filter
SCV
Supply Pump Fuel Filter
Fuel Tank Warning Light
Sistem Bahan Bakar
Fitur
NE Signal
Engine
G Signal EDU
ECU Injector
Various compensation
Max. 160MPa Pressure
Signals code
Limiter
HP3 Type
Fuel Common-rail
Supply
Pressure
Pump Sensor
Pressure
Switch Injector
Fuel
Filter
SCV
Supply Pump
Replacement Fuel Filter Warning light
filter element Fuel Tank Warning Light for fuel filter
Detects clogging and
only
filter fuel sedimenter
clogging
Common-rail System
Umum
– System ini dapat memberikan tekanan injeksi tinggi di
setiap kecepatan mesin.
NE Signal EDU
Engine
(Operates injector
G Signal ECU at high-speed)
Pressure
Various Limiter
Signals Common-rail
(Stores high-pressure fuel)
Fuel Pressure
Sensor
Injector
(Injects high-pressure fuel)
SCV
Supply Pump
(Generates high-pressure fuel) Fuel Tank
: High-pressure (Max. 160 Mpa/1631 kg/cm2)

Referensi
Umum
– Keuntungan common-rail system
Tekanan injeksi, volume dan timing

dikontrol secara elektronik Kontrol mesin yg akurat
Bahan bakar tekanan tinggi Atomisasi lebih baik
Menyimpan bahan bakar Injeksi tekanan tinggi

tekanan tinggi disemua kecepatan mesin
• High performance dan fuel economy

• Suara dan getaran rendah
• Emisi lebih bersih
Common-rail System
System Outline
Common-rail Diesel Conventional Diesel
Constant high pressure Instantaneously high pressure
Common-rail Pressure
Sensor
System
SCV Governor
Timer
ECU
Injection
Injector Pump
Supply Pump Nozzle
Injection Volume
ECU (Injector) Pump (Governor)
Control
Injection Timing
ECU (Injector) Pump (Timer)
Control
Injection Pressure According to rotational speed
Supply Pump (SCV)
Control and injection quantity
Pressurization Supply Pump Pump
Distribution Common-rail Pump
Injection Pressure Max. 160 MPa Approx. 15 MPa
Common-rail System
Lokasi
Depan
Injection Pipe Injector
Fuel Inlet Pipe
Common-rail
•Fuel Pressure Sensor
Supply Pump •Pressure Limiter
•SCV (Suction Control Valve)
•Fuel Temp. Sensor
Common-rail System
Supply Pump
– Mengirimkan tekanan tinggi ke common-rail
– Digerakkan oleh crankshaft
To Common-rail
(Outlet)
From Fuel Filter
(Inlet)
To Fuel Tank
(Return)
SCV
(Suction Control Valve)
Common-rail System
Supply Pump
– Konstruksi
Check Eccentric and Delivery

Valve Ring Cam Valve
Plunger
Feed
Pump
Fuel
Temp.
Sensor
SCV (Suction
Control Valve)
Common-rail System
Supply Pump
– Konstruksi
Ke fuel tank
(kembali)
Ring Cam
Plunger
Eccentric
Cam
Common-rail System
Supply Pump
– Aliran Bahan Bakar
Ke common-rail
Dari Fuel
Tank
Common-rail System
Supply Pump
– Aliran Bahan Bakar (referensi)
Click!
Movie
Common-rail System
Supply Pump
– Penghisapan dan pemompaan
Plunger A: Hisap Plunger A: Pompa

Plunger B: Pompa Plunger B: Hisap
Check
Valve
Plunger A
SCV
Plunger B
: Dari Feed Pump : Ke Common-rail

Common-rail System
Supply Pump
– Penghisapan dan pemompaan
Click!
Movie
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV kecil)
Fuel
Pumping
Mass
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV besar)
Fuel
Pompa
Mass
Referensi
Supply Pump
– Plunger membuat Negative
Pressure
kevakuman untuk
menghisap bahan bakar
sampai gelembung hilang
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV kecil)
Click!
Movie
Common-rail System
Supply Pump
– Kerja Fuel control (bukaan SCV besar)
Click!
Movie
Common-rail System
Supply Pump
– Bukaan SCV mengontrol volume pemompaan untuk
mengontrol tekanan bahan bakar
[Fuel Pressure Control]
Fuel Pressure
Sensor
Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Perhitungan Position Sensor
opening target injection
pressure
Accelerator Pedal
Position Sensor
Engine ECU
Common-rail System
Common-rail
– Menyimpan tekanan tinggi (Max. 160 MPa) yang
dikirim oleh supply pump
Pressure
Limiter
Fuel
Pressure
Sensor
Common-rail
Dari
Ke Injector Ke Fuel Tank
Supply Pump
Common-rail System
Common-rail
– Fuel pressure sensor
• Mendeteksi internal fuel pressure di common-rail
Output characteristic
Sensor Tip
Output Voltage (V)

4.04
2.44
1.0
0 90 190
Common-rail Pressure (MPa)
Common-rail
Pressure
Common-rail System
Injector
– Injeksi tekanan tinggi untuk atomisasi yang lebih baik
Injector
Compensation
Code
Kembali ke
Fuel Tank Dari Common-rail
0.14 mm
Common-rail System
Injector
– Konstruksi
Solenoid Coil
Dari
Kembali ke
Fuel Tank Common-rail
Piston
Nozzle
Spring
Nozzle
Needle
Common-rail System
Injector
– Dikontrol signal dari ECU
Solenoid
Solenoid
TWV
Small
Orifice Return
From
Common-rail Large
Orifice
Click!
Movie
Common-rail System
Injector
– Pilot injection mengurangi NOx dan suara mesin
Main
Injection Pilot
Volume
NOx dan
engine noise
Nilai
Pelepasan
Panas
TDC TDC
Pilot Conventional
Injection Control Injection Control
Common-rail System
EDU (Electronic Driver Unit)
– Mengendalikan injector saat kecepatan tinggi
EDU
Battery High
DC / DC Voltage
Converter
Command
Pulse
IJT
#1-4
Control
Circuit High-speed
IJF
operation
Confirmation
Engine Pulse Injector
ECU
Common-rail System
Diagnosis
– DTC untuk common-rail system
Area Kerusakan Detection Condition Fail-safe
DTC No. Item Pendeteksian Area Kerusakan

P0087 Fuel Rail/System Tekanan - •Open atau short pada fuel pressure sensor
(49) terlalu rendah circuit •Fuel pressure sensor •Engine ECU
P0088 Fuel Rail/System Tekanan – •Short pada supply pump (SCV) circuit •Supply
(78) terlalu tinggi pump (SCV) •Engine ECU
•Jalur bahan bakar high pressure

•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) Circuit Malfunction
•Open atau short pada fuel pressure sensor
P0192 Fuel Rail Pressure Sensor circuit
(49) Circuit Low Input •Fuel pressure sensor
•Engine ECU
(49) Circuit High Input
Common-rail System
Diagnosis
Trouble Area Kondisi Pendeteksian Fail-safe
DTC No. Item Pendeteksian Kondisi Pendeteksian

P0087 Fuel Rail/System Pressure - Fuel pressure sensor output voltage nilainya
(49) Terlalu rendah tidak berubah
P0088 Fuel Rail/System Pressure -

Tekanan melebihi 200 MPa (2039 kgf/cm2)
(78) Terlalu tinggi
Perbedaan tekanan common-rail sebelum dan

Terdeteksi kebocoran pada
P0093 setelah injeksi bahan bakar berbeda jauh dari
sistem Bahan Bakar – Bocor
(78) yang sudah di hitung ECU sebelum dan sesudah
besar
injeksi
P0190 Fuel Rail Pressure Sensor Fuel pressure sensor output voltage 0.55V atau
(49) Circuit Malfunction kurang, atau 4.9V atau lebih selama 0.5 sec.
(49) Circuit Low Input kurang selama 0.5 sec.
(49) Circuit High Input lebih selama 0.5 sec.
1 trip detection logic untuk semua DTC

Common-rail System
Diagnosis
Trouble Area Detection Condition Fail-safe
DTC No. Item Pendeteksian Fail-safe

(49) Terlalu rendah
Membatasi power mesin
(78) Terlalu tinggi
P0093 Terdeteksi kebocoran sistem Membatasi power mesin selama 1 min.,

(78) Bahan Bakar – Bocor besar kemudian mematikan mesin

(49) Circuit Malfunction

Circuit Low Input
Membatasi power mesin
(49)
(49) Circuit High Input
Common-rail System
Diagnosis
Area Kerusakan Detection Condition Fail-safe
DTC No. Item Pendeteksian Area Kerusakan
•Open atau short pada EDU circuit

P0200 •EDU
Injector Circuit / Open
(97) •Injector
•Engine ECU
•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)
Common-rail System
Diagnosis
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 Fuel Pump Control Circuit / Open atau short pada suction control valve
(97) Open circuit lebih dari 0.5 sec.
Terlalu banyak bahan bakar:

P0627
Fuel Pump System Tekanan bahan bakar melewati target
(78) walaupun ECU telah menutup SCV.
P1229 Injector Correction Circuit

Injector compensation code tidak ter-register
(78) Malfunction (EEPROM)
Open atau short pada EDU atau injector circuit.

Setelah mesin hidup, tak ada injection
P1601
Injector Circuit / Open 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

Common-rail System
Diagnosis
Trouble Area Detection Condition Fail-safe
DTC No. Detection Item Fail-safe
P0200
Injector Circuit / Open
(97)
P0627 Fuel Pump Control Circuit Membatasi Power Mesin

(78) / Open
P1229
Fuel Pump System
(78)
Injector Correction
P1601
Circuit Malfunction -
(89)
(EEPROM)
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)
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
Inisialisasi
dan Kalibrasi
Penggantian
Data karakteristik output
supply pump BARU
Inisialisasi hanya dibutuhkan jika mesin tak bisa hidup setelah penggantian
Service Point
Supply Pump Initialization and Calibration
– Prosedur
Inisialisasi
Setelah Engine
Penggantian, stop CG TC
for 3 min.
DLC3 Resetting
IG Turn Short IG ON IG OFF
Start engine Start engine
Kalibrasi Learning
THW > 60 °C
THF > 20 °C
Warm-up Idling 1 menit IG OFF

Service Point
Common-rail Replacement
– Common-rail tak boleh di bongkar
(Penggantian Assembly)
Jangan
Dibuka
Fuel Pressure !
Sensor
Pressure
Limiter
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
ECU mesin
Masukan
nomor
Ganti ECU
mesin
Semua nomor
injektor
Service Point
– Garis besar proses registrasi
Ketika menganti injector(s) Ketika mengganti ECU
Catat data compensation code

Ganti injector(s)
code data
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

Service Point
– Catat injector compensation codes
(sebelum mengganti engine ECU)
Save the
Compensation
Codes
Click!
Service Point
Select
Powertrain

Engine and ECT

Utility

Injector Compensation
“Next”
Service Point
“Next”
Service Point
“Read
Compensation
Code”
Service Point
“Next”
Service Point
Select
cylinder No.
Service Point
“Next”
Service Point
Service Point
“Save”
Service Point
Periksa bahwa
compensation code
benar
“Save”
Service Point
Service Point
Selesai menyimpan
No.1 cylinder’s
injector
compensation code
Baca dan simpan

injector Selesai
compensation
codes yang lain
Service Point
Service Point
– Registrasi injector compensation codes
(setelah penggantian)
Set the
Compensation
Codes
Click!
Service Point
Select
Powertrain

Engine and ECT

Utility

Injector Compensation
“Next”
Service Point
“Next”
Service Point
“Set
Compensation
Code”
Service Point
“Next”
Service Point
Select
cylinder No.
Service Point
“Next”
Service Point
“Input” “Open”
(Input manually) (Input saved data)
Service Point
Input
Nomor 1
30
“Input”
(Input manually)
Service Point
Input
Nomor 1
30
“OK” 01BBC0DFED00E70D000000000000A2
Service Point
“Open”
Service Point
Service Point
Periksa bahwa
compensation code
benar
“Next”
Service Point
Service Point
Selesai setting
No.1 cylinder’s
injector
compensation code
Set injector Selesai

compensation
codes yang
lainnya
Service Point
Service Point
Penggantian parts baru
– Parts yang tidak boleh dipakai ulang (huruf merah)
Nozzle
Injector
Holder Seal
Back-up Ring
O-ring
Nozzle Seat Head Cover
Gasket
O-ring
Leakage Pipe
Supply Pump
Service Point
Penggantian pipa baru
– Ganti dengan pipa baru jika mengganti komponen-
komponen berikut
Injection
Pipes
Komponen yang Pipa yang

diganti diganti
• Injector
Injection
• Common-rail
Pipes
• Cylinder Head
•Supply Pump
•Common-rail
•Cylinder Block Fuel Inlet
•Cylinder Head Pipe
•Cylinder Gasket
•Gear Case
Fuel Inlet Pipe

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 nya [90405-06167]
gelembung
Nozzle
Leakage
Pipe
250 kPa
Lepas
SST (09992-00242) Check Valve

(Part No. 23122-27010)
Service Point
Periksa kebocoran (Sistem Bahan Bakar)
1, Mesin berhenti
Tak ada kebocoran
2, Start mesin
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
Service Point
Power Balance Check
– Gunakan Intelligent Tester II (Active Test) untuk
pemeriksaan power balance
Active Test
•Injector Cut #1
•Injector Cut #2
•Injector Cut #3
•Injector Cut #4
Tegangan
Tinggi
Jangan melepas
konektor injektor
Sistem Bahan Bakar
Saringan Bahan Bakar
– Hanya mengganti element saringan
Priming Fuel Filter
Pump Warning Switch
Ke Supply Pump
Dari Fuel Tank
Mur Pengencang
Filter Housing
(Plastik)
Filter Element
Drain Cock
Sistem Bahan Bakar
VIDEO D-4D
Sistem Bahan Bakar
Saringan Bahan Bakar
– Konstruksi
Priming Fuel Filter
Pump Warning Switch
Dari Fuel Tank Ke Supply Pump
Mur Pengencang
Filter Element Filter Housing

(Plastik)
Fuel Sedimenter Level

Warning Switch
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
Tersumb
at
Kombinasi Meter
Saringan
- Jarak Penggantian Saringan Bahan Bakar -

Jika fuel filter warning light menyala
Sistem Bahan Bakar
Fuel Filter Warning
– System Diagram
Kombinasi Meter
Vehicle Speed
Sensor
Fuel Filter Meter
Warning Switch ECU
Fuel Filter
Warning Light
Ke Supply Pump
Filter Element
Fuel Filter Fuel Sedimenter Level Warning Switch

Sistem Bahan Bakar
Fuel Filter Warning
– Fuel filter warning switch akan OFF saat tekanan
outlet filter menurun (vakum)
Fuel Filter Fuel Filter
Warning Warning
Switch Switch
ON Meter OFF Meter
ECU ECU
Diaphragm
Ke Supply Pump Ke Supply Pump
Filter Element Negative

Pressure
Fuel Filter Normal Fuel Filter Tersumbat

(Switch: ON) (Switch: OFF)
Sistem Bahan Bakar
Fuel Filter Warning
– Kondisi warning light untuk fuel filter / fuel sedimenter
Warning
Warning Prioritas
Method
Sedimenter
Warning 1
Berkedip
Fuel Filter
Warning 2
ON
Sistem Bahan Bakar
Fuel Filter Warning
– Kondisi Pendeteksian
Setelah pengemudian 30 menit atau lebih
Kondisi Fuel Filter Warning Switch

Terdeteksi OFF
OFF selama 10
atau sebanyak 2 kali
menit atau lebih
dalam 1 trip
Warning light tetap ON sampai dilakukan reset

Service Point
Fuel Filter Warning
– Jika warning light menyala, ganti elemen Saringan
Bahan Bakar dan reset warning light
Buka elemen saringan
Longgarkan
Tutup Tanki
Bahan Bakar
Service Point
Fuel Filter Warning
– Buka elemen Saringan Bahan Bakar
Inlet hose
Fuel
Level
Drain
Cock
Lepas Keluarkan bahan bakar untuk
konektor menurunkan permukaan nya
dan hose
Service Point
Fuel Filter Warning
– Buka elemen Saringan Bahan Bakar
Obeng
Longgarkan pengunci Lepas dengan tangan

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

Bahan Bakar
Rumah Element
Pasang O-ring baru
Buka tutupnya, lepas

elemen
Service Point
Fuel Filter Warning
– Pasang Saringan Bahan Bakar
Tanda
Tanda
Elemen
baru
Pasang elemen baru dan

pasang tutup filter Kencangkan pengunci sampai
(luruskan tanda) tanda nya lurus
Service Point
Fuel Filter Warning
– Pasang Saringan Bahan Bakar
Inlet Hose
Kencangkan tutup
bahan bakar
Hubungkan
Service Point
Fuel Filter Warning
– Pasang Saringan Bahan Bakar / Reset warning light
Reset warning light
dalam
3 - 60 detik 3 detik.
IG ON
OFF
Pasang
Service Point
Fuel Filter Warning
– Pasang Saringan Bahan Bakar / Reset warning light
Keluarkan udara pada

Sistem Bahan Bakar
pompa
Selesai
Sistem Pengisian
Alternator Pulley
• Untuk menyerap fluktuasi mesin, digunakan one-
way clutch pada pulley 　 alternator
Spring Sprag
Sistem Pengisian
Alternator Pulley
– Mekanisme penyerapan fluktuasi mesin
One-way Crankshaft Pulley

Clutch Speed
Locked
One-way
Clutch
Free
Alternator
Pulley Speed
Pulley Speed (rpm)
Engine
Fluctuation
Time
Service Point
Alternator Pulley
– Gunakan SST, saat membuka atau memasang
alternator pulley
SST (09820-63020):
2 parts
Buka
Service Point
Alternator Pulley
– Alternator pulley cap hanya sekali pakai
Alternator Pulley Cap

(Non-reusable Part)
Sistem Serpentine Belt Drive
Serpentine Belt Drive
– Single V-ribbed belt
Air Conditioner Idler Pulley
Compressor Pulley
Water Pump Pulley
Idler Pulley
Alternator Pulley Crankshaft Pulley

dengan Shock
Absorbing Function
Idler Pulley untuk

Automatic Tensioner
- Jarak penggantian -
Indonesia
2KD-FTV baru 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
Referensi
– Intake shutter valve position sensor
Magnet
Hall IC 5
Output Voltage (V)

VC 3.51
VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full Open)
Intake Shutter
Valve Position Opening Angle (°)
Sensor
Referensi
Accelerator Pedal
– Non-contact type accelerator pedal position sensor
Accelerator Pedal
Position Sensor
Referensi
Accelerator Pedal
– Using magnet dan hall IC
VCP1
Magnets
VPA1
Output Voltage (V)

EP1 5
VPA2
VCP2
Hall
IC VPA2
VPA1
EP2 0
Full Close Full Open
Accelerator Engine Accelerator Pedal Depressed Angle
Pedal Position ECU
Sensor

2.5L Diesel Engine System Overview

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2.5L Diesel Engine System Overview

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Model Outline Mesin 2KD-FTV Chassis Body Body Electrical

Lokasi Nomor mesin

•SLLC Fuel Filter

Normal Setiap 5,000km atau 6 bulan 

Normal Setiap 10,000km atau 12 bulan

Kondisi Posisi Intake Shutter Valve

Intake Shutter Valve

Waste Gate Actuator

: High-pressure (Max. 160 Mpa/1631 kg/cm2)

Tekanan injeksi, volume dan timing

Bahan bakar tekanan tinggi Atomisasi lebih baik

Menyimpan bahan bakar Injeksi tekanan tinggi

• High performance dan fuel economy

Injection Pipe Injector

Fuel Inlet Pipe

Check Eccentric and Delivery

Plunger A: Hisap Plunger A: Pompa

: Dari Feed Pump : Ke Common-rail

Output Voltage (V)

DTC No. Item Pendeteksian Area Kerusakan

•Jalur bahan bakar high pressure

P0190 Fuel Rail Pressure Sensor

DTC No. Item Pendeteksian Kondisi Pendeteksian

P0088 Fuel Rail/System Pressure -

Perbedaan tekanan common-rail sebelum dan

1 trip detection logic untuk semua DTC

DTC No. Item Pendeteksian Fail-safe

P0093 Terdeteksi kebocoran sistem Membatasi power mesin selama 1 min.,

P0190 Fuel Rail Pressure Sensor

P0192 Fuel Rail Pressure Sensor

DTC No. Item Pendeteksian Area Kerusakan

•Open atau short pada EDU circuit

•Open atau short pada (SCV) circuit

•Short pada supply pump (SCV) circuit

Open atau short pada EDU atau injector circuit.

Terlalu banyak bahan bakar:

P1229 Injector Correction Circuit

Open atau short pada EDU atau injector circuit.

1 trip detection logic untuk semua DTC

DTC No. Detection Item Fail-safe

P0627 Fuel Pump Control Circuit Membatasi Power Mesin

supply pump discharge

Start engine Start engine

Warm-up Idling 1 menit IG OFF

Ketika menganti injector(s) Ketika mengganti ECU

Catat data compensation code

Masukan code compensation

Hapus DTC P1601 Hapus DTC P1601

Registrasi selesai Registrasi selesai

Baca dan simpan

Set injector Selesai

Nozzle Seat Head Cover

Komponen yang Pipa yang

Fuel Inlet Pipe

SST (09992-00242) Check Valve

3, Lepas selang balik dari common-rail

Tak bocor (dari selang balik)

4, Dengan Intelligent Tester II, lakukan

Tak ada kebocoran

Sistem Bahan Bakar

Dari Fuel Tank Ke Supply Pump

Filter Element Filter Housing