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TOYOTA Models '03 4Runner Engine (Except 1GRFE).ppt

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    • EngineEngine2UZ-FE2UZ-FE1KZ-TE1KZ-TE 2UZ-FE EnginenEngine OverallnIntake & Exhaust SystemnFuel SystemnCharging SystemnEngine Control System-A 2UZ-FE EnginenEngine Overall•Engine SpecificationItem’03 4Runner’03 SequoiaNo. of Cylinders and Arrangement8-Cylinder, V-typeValve Mechanism32-Valve DOHC, Gear/Belt DriveFuel SystemSFIDisplacement cm3 (cu. in.)4664 (284.5)Bore x stroke mm (in.)94.0 x 84.0 (3.70 x 3.31)Compression Ratio9.6 : 1Max. Output (SAE-NET)175 kW @ 4800 rpm(235 HP @ 4800 rpm)179 kW @ 4800 rpm(240 HP @ 4800 rpm)Max. Torque (SAE-NET)434 Nm @ 3400 rpm(320 ftlbf @ 3400 rpm)427 Nm @ 3400 rpm(315 ftlbf @ 3400 rpm)Fuel Cetan Number91 or moreOil GradeAPI SL, EC or ILSAC-A 2UZ-FE EnginenIntake & Exhaust System•Carbon Filter–Carbon filter adsorb HC in intake system to reduce evaporative emissionAir CleanerCarbon Filter(Maintenance-free)Air Flow-A 2UZ-FE EnginenIntake & Exhaust System•TWC–Three TWCs are used to meet LEV ITWCs-A 2UZ-FE EnginenFuel System•Fuel Tank–Multiplex layer plastic made type fuel tank is used to comply the LEV II regulationsFrontCross SectionOutsideInsideMultiplex layer-A 2UZ-FE EnginenFuel System•Fuel Tank Cap–Quick-type fuel tank cap has been adopted to improve usability-A 2UZ-FE EnginenCharging System•Alternator–Compact and lightweight Segment Conductor type alternator is usedSegment ConductorTwistedJoined Segment Conductor SystemJoinedA Cross Section DiagramAStator-A 2UZ-FE EnginenEngine Control System•ETCS-i •Evaporative Emission Control System•Cranking Hold Function •Diagnosis -A 2UZ-FE EnginenEngine Control System•ETCS-i–In the new 2UZ-FE engine, the link-less type ETCS-i is usedAccelerator Pedal Position SensorThrottle Position SensorThrottle Control Motor’03 4RunnerECM-A Throttle Position Sensor2UZ-FE EnginenEngine Control System•ETCS-i–A no-contact type throttle position sensor is used Throttle Control MotorReduction GearsThrottle ValveHall ICsMagnets-A 2UZ-FE EnginenEngine Control System•ETCS-i–Throttle position sensor converts into electric signals the magnetic flux density Throttle Valve Opening AngleFull OpenFull CloseVTA1VTA2Output Voltage (V)05ECMVTA1VTA2E2VCHall ICsMagnetsThrottle Valve Opening AngleFull OpenFull CloseVTAVTA2Output Voltage (V)05ECMVTAVTA2E2VCHall ICMagnet-A 2UZ-FE EnginenEngine Control System•ETCS-i–A no-contact type accelerator pedal position sensor is usedAccelerator Pedal ArmHall ICsMagnets-A 2UZ-FE EnginenEngine Control System•ETCS-i–Accelerator pedal position sensor converts into electric signals the magnetic flux density Accelerator Pedal Depressed AngleFull OpenFull CloseVPAVPA2Output Voltage (V)05ECMVPAVPA2EPA2EPAHall ICsMagnetsVCPAVCP2-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–The construction is changed to comply with the LEV-II evaporative emission regulationsCharcoal CanisterCanister Close ValveVapor Pressure SensorTo Intake ManifoldPurge ValveTank Pressure ValveRestrictor PassageAir FilterThe construction is simpler than the conventional vacuum type-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–LocationCharcoal CanisterCanister Close ValveVapor Pressure SensorPurge ValveTank Pressure ValveAir FilterService Port-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–Charcoal canister assemblyCanister Closed ValveTank Pressure ValveCharcoal Canister(3.0 liters)From Fuel TankTo Fresh Air LineTo Intake Manifold-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–The vapor guide prevents the vapor gas without passing through the activated charcoalWith vapor guide (’03 4Runner)Without vapor guide (Conventional type)Include vapor gas*To Intake ManifoldFrom Fuel TankTo Intake ManifoldFrom Fuel TankClean airAbsorb vapor gas*: It will affect the air-fuel ratio control of the engineVapor Guide-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–Tank pressure valve controls the flow rate of the vapor gas from fuel tank to charcoal canisterWhen refueling (Tank pressure is large)Tank Pressure ValveVapor Gas (From Fuel Tank)From Fuel TankRestrictor Passage-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–The restrictor passage prevents the large amount of vacuum that is created during system monitoring from entering the fuel tankFrom Fuel TankRestrictor PassageRestrictor PassageIf the large amount of vacuum enters the fuel tank during system monitoring, system monitoring is not performed normallyVacuum-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–The air filter prevents dust and debris in the fresh air from entering the systemTo Fresh AirTo Charcoal CanisterThe air filter is maintenance-free-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–Stored fuel vapors are purged from the charcoal canister when the purge valve is opened by ECMECMOPENOPENTo Intake ManifoldAtmosphereDutyStored fuel vapors-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–When refueling, the fuel vapors enter to the charcoal canister and they are cleanedECMCloseOPENOPENThe internal pressure increasesThe fuel vapors are Cleaned-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–When the initial conditions are met, the ECM introduces a vacuum into the system and monitors system to detect system malfunctionP1Initial conditions are metP2P1’0 mmHgFuel Tank PressurePurge ValveCanister Closed ValveThe ECM monitors the amount of pressure increase in the fuel tank OpenCloseOpenCloseValue BValue A-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–System monitoring (Step1)The ECM measures the amount of pressure increase (P1) in the fuel tankFuel Tank PressurePurge ValveCanister Closed ValveP10 mmHg15 secs.P1CloseClose-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–System monitoring (Step2)The ECM opens the purge valve and introduces a vacuum into the fuel tankFuel Tank PressurePurge ValveCanister Closed ValveOpenClose-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–System monitoring (Step3)Fuel Tank PressurePurge ValveCanister Closed ValveValue BValue ABelow value A The ECM measures the amount of pressure increase (P2)in the fuel tankP2P25 secs.Value BCloseClose-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–System leak judgmentP2 MeasurementP2 > Reference Value*Presumes presence of system leakP1 is smallJudges presence of system leak*: Reference value is stored in the ECMP2 < Reference Value*Judges absence of system leakP1 is largeJudges P1 again (P1’)Normal system control-A P1’ is smallJudges presence of system leakP1’ MeasurementThe MIL illuminates and ECM stores the following DTCs in its memoryLevel of LeakDTCVery small, small or medium leakP0442 and/or P0456Large leakP0441, P0442 and P0446P1’ is largeRepeats judgment-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–VSV monitoring (Normal condition)PurgingSystem monitoringPurge ValveSystem leak judgmentCanister Closed ValveFuel Tank PressureOpenCloseOpenClose-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–VSV monitoring (Purge valve open malfunction)DTC P0441 is memorized, The MIL illuminatesWhen the ECM is measuring the P1 value, the pressure in the fuel tank drops rapidlyIt remains in a constant, slight vacuum stateMalfunction JudgmentPurge ValveCanister Closed ValveFuel Tank PressureNormal ConditionOpenEngine Starting-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–VSV monitoring (Purge valve close malfunction)DTC P0441, P0442 and P0446 is memorized, The MIL illuminatesPurge ValveCanister Closed ValveFuel Tank PressureCloseMalfunction JudgmentThe pressure does not changeNo vacuum is introduced-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–VSV monitoring (Canister closed valve open malfunction)Purge ValveCanister Closed ValveFuel Tank PressureOpenDTC P0441, P0442 and P0446 is memorized, The MIL illuminatesMalfunction JudgmentA slight vacuum is createdIt is not possible to completely introduce a vacuum-A 2UZ-FE EnginenEngine Control System•Evaporative Emission Control System–VSV monitoring (Canister closed valve close malfunction)Purge ValveCanister Closed ValveFuel Tank PressureDTC P0446 is memorized, The MIL illuminatesMalfunction JudgmentA large amount of vacuum is introduced Close-A 2UZ-FE EnginenEngine Control System•Cranking Hold Function–Once the ignition switch is turned to the START position, this control continues to operate starter until engine startsStarterIgnition SwitchEngine starts“Start”OperateOperates Automatically“ON”Stop-A 2UZ-FE EnginenEngine Control System•Cranking Hold Function–System DiagramSTACCNETHWPark/Neutral Position SwitchAudio & IlluminationStarter RelayStarterEngine Coolant Temp. SensorCrankshaft Position SensorACC Cut RelayIgnition SwitchECM-A STACCNETHWPark/Neutral Position SwitchAudio & IlluminationStarter RelayStarterEngine Coolant Temp. SensorCrankshaft Position SensorACC Cut RelayIgnition SwitchECM2UZ-FE EnginenEngine Control System•Cranking Hold Function–The ACC cut relay cuts off the ACC circuit while engine is cranking to prevent the accessory illumination from operating intermittently-A 2UZ-FE EnginenEngine Control System•Cranking Hold Function (Operation)Ignition SwitchStarter RelayACC Cut RelayNE SignalTimeStart: Without this system: With this systemAutomatically ControlledJudgment0.2 sec. or moreON-A 2UZ-FE EnginenEngine Control System•Cranking Hold Function–The maximum cranking time will be changed with engine coolant temp.Reference Value!!Engine Coolant Temp.(°C (°F))Max. Cranking Time (sec.)100 (212)Approx. 20 (32)Approx. 5-30 (-22)Approx. 25Engine Coolant Temp. (C)Max. Cranking Time (sec.)When engine coolant temp. is lower, the time limit is longer50Confidential-A 2UZ-FE EnginenEngine Control System•Cranking Hold Function–If the engine is already running, the ECM will not energize to the starter relay Starter RelayNE SignalStartIgnition SwitchONOFFEngine is already running700 rpm-A 2UZ-FE EnginenEngine Control System•Cranking Hold Function–If the engine speed becomes 1200 rpm or more while cranking, the ECM turns off a starter relay to prevent starter overrunTime1200 rpmDriver operates intentionallyOFFStartIgnition SwitchON-AStarter RelayNE Signal 2UZ-FE EnginenEngine Control System•Cranking Hold Function–When a starter is intentionally operated by the driver, the ECM turns off a starter relay after 30 sec. in order to prevent starter overheating30 sec. Driver operates intentionallyOFFEngine does not start (Problem)StartIgnition SwitchONTime-AStarter RelayNE Signal 2UZ-FE EnginenEngine Control System•Diagnosis –To comply with the OBD-II regulations, all the DTC have been made to correspond to SAE controlled codes. Some of the DTC have been further divided into smaller detection area than in the past, and new DTC have been assigned to them.DTCDetection ItemP0135Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)DTCDetection ItemP0031Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 1)P0032Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 1)ExampleOld DTCNew DTC-A 1KZ-TE EnginenEngine OverallnEngine PropernLubrication SystemnIntake & Exhaust SystemnFuel SystemnEngine Control System-_ 1KZ-TE EnginenEngine Overall•Engine SpecificationItem’03 4Runner’02 4RunnerNo. of Cylinders and Arrangement4-Cylinder, In-lineValve Mechanism8 Valve OHC, Gear/Belt DriveCombustion ChamberSwirl TypeManifoldsCross-FlowFuel SystemDistributor TypeDisplacement cm3 (cu. in.)2982 (181.9)Bore x stroke mm (in.)96 x 103 (3.78 x 4.06)Compression Ratio21.2 : 1Max. Output EEC?92 kW @ 3600 rpmMax. Torque EEC?295 Nm @ 2400 rpmFuel Cetan Number48 or moreOil GradeAPI CD or Better-_ 1KZ-TE EnginenEngine Proper•Flywheel–Flywheel size is increased to meet the clutch size up (10.5”  11”)-_ 1KZ-TE EnginenLubrication System•Oil Pan–No.1 oil pan is made of aluminum alloyOil Pan CoverNo.1 Oil PanNo.2 Oil Pan-_ 1KZ-TE EnginenIntake & Exhaust System•Intercooler–Intercooler is used for all modelscIntercooler ProtectorIntercooler-_ 1KZ-TE EnginenIntake & Exhaust System•Intercooler Protector–Intercooler protector is on intercoolerEngine FoodAirIntercoolerIntercooler ProtectorEngine-_ 1KZ-TE EnginenFuel System•Fuel Tank–Multiplex layer plastic made type fuel tank (main tank) is used for 5 door modelFrontCross SectionOutsideInsideMultiplex layer-_ 1KZ-TE EnginenFuel System•Fuel Tank Cap–Quick-type fuel tank cap has been adopted to improve usability-_ 1KZ-TE EnginenEngine Control System•ETCS-i–A no-contact type accelerator pedal position sensor is usedAccelerator Pedal ArmHall ICsMagnets-_ 1KZ-TE EnginenEngine Control System•ETCS-i–Accelerator pedal position sensor converts into electric signals the magnetic flux density Accelerator Pedal Depressed AngleFull OpenFull CloseVPAVPA2Output Voltage (V)05Engine ECUVPAVPA2EPA2EPAHall ICMagnetVCPAVCP2-_ 。

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