Описание двигателя

Описание двигателя
Характеристики 4GR-FSE
3 Цепи газораспределения
Свечи зажигания с длинной юбкой
Масляный фильтр со сменным элементом
Датчик VVT с MRE

Описание двигателя
Характеристики 4GR-FSE
Два механизма VVT-i
Проставка рубашки охлаждения
Гидрокомпенсатор клапанного зазора
Поворотный электромагнитный клапан системы ACIS
Плита распредвалов
Клапан управления впуском воздуха
Топливный насос высоко давления
Непосредственное впрыскивание (D-4)
Форсунка
с щелевым соплом

Описание двигателя
Основные характеристики

Engine Proper
Cylinder Head
Camshaft housing to simply the cylinder head structure
Camshaft bearing cap for IN and EX is one piece
Cylinder Head Cover
Cylinder Head Cover Gasket
Camshaft Bearing Cap
Camshaft Housing
Cylinder Head
Cylinder Head Gasket
For IN and EX is one piece

Service Point (Engine Proper)
Cylinder Head
Camshaft and camshaft housing installation
LH Bank
Step1
: Temporary tighten (Torque: 10N·m [102kgf·cm])
: Tightening order
X

Service Point (Engine Proper)
Cylinder Head
Camshaft and camshaft housing installation
LH Bank
Step2
: Tighten (Torque: 28N·m [286kgf·cm])
: Tightening order
X

Service Point (Engine Proper)
Cylinder Head
Camshaft and camshaft housing installation
LH Bank
Step3
: Tighten (Torque: 16N·m [163kgf·cm])
: Tightening order
X

Engine Proper
Cylinder Block
Water jacket spacer optimizes the cylinder bore temp. to reduce friction
Water Jacket Spacer (LH)
Water Jacket Spacer (RH)
Water jacket spacer reduces coolant flow
With
Without
Overcool
Low Oil Viscosity
↓
Low Friction
High Oil Viscosity
↓
High Friction

Engine Proper
Cylinder Block
Spiny liner is used to increase cooling performance
Approx. 1.0 mm (0.039 in.)
Liner Cross Section
Outside
Cylinder Liner
Cylinder Block

Engine Proper
Piston
Optimal piston head shape to promote the mixture of fuel and air
Injector

Engine Proper
Bearing
Bearing without bearing claw is used for crankshaft bearings and connecting rod bearings
Without bearing claw

Service Point (Engine Proper)
Installation of Crankshaft Upper Bearing
Bearing position should be centered to the cylinder block journal to align the oil hole
Oil Hole
Upper Bearing
[OK]
[NG]
Lubrication Holes
Center

Service Point (Engine Proper)
Installation of Crankshaft Lower Bearing, Connecting Rod Upper and Lower Bearings
Bearing should be positioned in center and measure the position
Difference Between “B” and “C”: 0.7 mm (0.028 in.) or less
Vernier Caliper

Service Point (Engine Proper)
Crankshaft Bearing (upper and lower)
Combination of different width of the Bearings
No.1 and No.4 Journals
No.2 and No.3 Journals
18.0 mm
(0.709 in.)
21.0 mm
(0.827 in.)

Valve Mechanism
General
Three timing chains to drive intake and exhaust camshafts of each bank
Intake Camshaft
Exhaust Camshaft
Primary Chain
VVT-i Controller (for Exhaust)
Secondary Chain (RH)
Primary Chain Tensioner
Secondary Chain Tensioner
Hydraulic Lash Adjuster
VVT-i Controller (for Intake)

Valve Mechanism
Camshaft
VVT-i system is used for intake & exhaust camshafts (Dual VVT-i)
VVT-i Controller
VVT-i Controller
Intake
Exhaust
Assist Spring
Camshaft Timing Rotor

Valve Mechanism
Camshaft
RH bank exhaust camshaft is provided with the cam to drive the high-pressure fuel pump
RH Bank
Intake Camshaft
Exhaust Camshaft
High-Pressure Fuel Pump

Valve Mechanism
Timing Chain
Three timing chains to drive intake and exhaust camshafts of each bank
Crankshaft
Idler Sprocket
Automatic Tensioner for Secondary Chain (RH)
Automatic Tensioner for Secondary Chain (LH)
Automatic Tensioner for Primary Chain
Primary Chain
Secondary Chain (RH)
Secondary Chain (LH)

Valve Mechanism
Chain Tensioner
Primary chain tensioner
Ratchet type non-return mechanism
Service hall for remove and replace

Valve Mechanism
Chain Tensioner
2 secondary chain tensioners are used for left and right bank
Left Bank
Spring
Ball
Oil Pressure
(from cylinder head)
Pin (Stopper)
Chain Tensioner

Reference (Valve Mechanism)
Hydraulic Lash Adjuster
Maintaining a constant zero valve clearance through use of oil pressure and spring force
Oil Passage
Plunger
Oil Passage
Check Ball Spring
Check Ball
Plunger Spring
Low Pressure Chamber
High Pressure Chamber

Reference (Valve Mechanism)
Hydraulic Lash Adjuster
Start cam lift, plunger is pressed and oil in high pressure chamber is kept
High Pressure Chamber
Plunger

Reference (Valve Mechanism)
Hydraulic Lash Adjuster
Then the rocker arm pushes the valve by using hydraulic lash adjuster as a fulcrum
Fixed
High Pressure Chamber
Plunger

Reference (Valve Mechanism)
Hydraulic Lash Adjuster
Plunger pushes back, check valve is opened and fills up oil
High Pressure Chamber
Body
Check Ball
Plunger

Zero Valve Clearance
Reference (Valve Mechanism)
Hydraulic Lash Adjuster
Plunger is pushed up, then, valve clearance is maintained at zero
Plunger Spring
Plunger

Reference (Valve Mechanism)
Hydraulic Lash Adjuster
Operation

Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
1. Pushing check ball down by using SST
Hydraulic Lash Adjuster
SST: 09276-75010

Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
2. Immerse hydraulic lash adjuster in clean engine oil, then compress and return the plunger with SST 5 to 6 times
Clean Engine Oil

Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
3. Press the plunger by finger and check the blockage of plunger

Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
If plunger is compressed after 3 times trial, replace to new one

Lubrication System
Oil Delivery Pipe
Oil delivery pipe is used to lubricate cam and rocker arm
Oil Delivery Pipe
Cylinder Head Cover

Lubrication System
Oil Filter (2WD)
Element replacing type oil filter is used
Oil Filter Cap
Oil Filter Element
Oil Pan No.1
Cut Out Portion
Front
Cap Rib Portion

Service Point (Lubrication System)
Oil Filter (2WD)
Oil filter replacement
Removal
Loosen the filter cap for approx. 4 rev.
Remove filter element
SST:
09228-06501
Align the cap rib vertically and drain oil
Rib

Service Point (Lubrication System)
Oil Filter (2WD)
Oil filter replacement
Removal
Remove oil filter cap and filter element
Remove filter element and O-ring from filter cap
O-ring

Service Point (Lubrication System)
Oil Filter (2WD)
Oil filter replacement
Installation
Set new filter element and O-ring
New
New
Install filter cap using SST
Install filter element

Service Point (Lubrication System)
Oil Filter (2WD)
Oil filter replacement
Installation
Refill engine oil
Run the engine and check oil leakage
No Leakage

Intake and Exhaust System
ACIS Valve
Rotary solenoid type ACIS valve is used
ACIS valve is unified by laser-welding
Plastic
Laser-welding
Rotary Solenoid Type ACIS Valve

Reference (Intake & Exhaust System)
ACIS Valve
Rotary solenoid type ACIS valve is used
Valve
Rotary Solenoid Type Motor
Magnet
Shaft
Stator
ACIS Valve

Intake and Exhaust System
Intake Air Control Valve
Intake air control valve is operated by DC motor
DC Motor
Intake Air Control Valve
Intake Manifold
Linkage
Position Sensor

Valve is closed at low engine speed, or cold engine start
Intake and Exhaust System
Intake Air Control Valve
Operation
Intake Air
DC Motor
Accelerator Pedal Opening
Engine Speed
Water Temp.
Open / Close
Engine ECU
(ECM)
Valve Position

D-4 System
General
4GR-FSE engine uses D-4 System
D-4 (Direct injection 4-stroke gasoline engine)

D-4 System
System Diagram
High-Pressure Fuel Pump
Injector
Fuel Pressure Sensor
Fuel Tank
Delivery Pipe
Fuel Pump
Pressure Regulator
: 4 – 13 MPa
: 400 kPa
Pulsation Damper
SCV
Relief Valve
Jet Pump
Engine ECU (ECM)
EDU

D-4 System
Difference from usual gasoline EFI
Injector
Slit-nozzle type
Injection pressure is 4 –13 MPa
Installed on the combustion chamber
High Pressure Fuel Pump
Fuel pressure sensor is provided to delivery pipe
EDU for high speed injector operation

Reference
Features of D-4 System
Direct Injection
High Pressure Injection
Slit-nozzle Injector
Fuel does not adhere to the intake port
Higher atomization of fuel
Improved volumetric efficiency
Expanded knocking limit
Piston head shape is changed for D-4 system
High Performance
Clean Emission
Better Fuel Economy

D-4 System
Location
High-Pressure Fuel Pump
Injector
Fuel Pressure Sensor
Delivery Pipe
EDU
Pulsation Damper

D-4 System
High-Pressure Fuel Pump
Supplies the high pressure fuel to the delivery pipe
SCV (Spill Control Valve)
from Fuel Tank (0.4 MPa)
to Delivery Pipe (4-13 MPa)
Pulsation Damper
Return to fuel tank
Lifter

D-4 System
High-Pressure Fuel Pump
Fuel control operation (SCV close timing is late)
Plunger Lift
SCV
Open
Close
Close
ON
Open
(OFF)
Open
(OFF)
[Suction]
[Inactive]
Check Valve
SCV
to Delivery Pipe
from Fuel Tank
[Pumping]

D-4 System
High-Pressure Fuel Pump
Fuel control operation (SCV close timing is early)
Plunger Lift
SCV
Open
Close
Close
(ON)
Open
(OFF)
Open
(OFF)
[Suction]
[Inactive]
[Pumping]
Check Valve
SCV
to Delivery Pipe
from Fuel Tank

D-4 System
High-Pressure Fuel Pump
The SCV close timing regulates the pumping volume to control fuel pressure
Controls SCV close timing
Fuel pressure
(Feedback)
SCV
Fuel Pressure Sensor
Crankshaft Position Sensor
Engine ECU (ECM)
[Fuel Pressure Control]
Calculation of target pressure

D-4 System
Delivery Pipe
Stores high-pressure fuel (4 – 13 MPa) produced by high-pressure fuel pump
Fuel Pressure Sensor
Relief Valve
Delivery Pipe
From Fuel Pump (High Pressure)
Return to Fuel Tank
Injector

D-4 System
Delivery Pipe
Fuel pressure sensor
Fuel Pressure
0
19.6
0.5
4.5
Delivery Pipe Pressure (MPa)
Output Voltage (V)
Output characteristic
Sensor Portion
9.8
2.5

D-4 System
Injector
High pressure, slit-nozzle type injector
Slit-nozzle

D-4 System
Injector
Slit-nozzle makes sector formed injection
Sector Formed Injection
0.71 mm
(0.028 in.)
A
0.15 mm
(0.006 in.)
A Cross Section
Slit-nozzle

D-4 System
Injector
Construction
Injector Seal
Back-up Ring
O-ring
Nozzle-needle
from Delivery Pipe
Coil

Service Point (D-4 System)
Injector
When remove the injector from cylinder head, replace the injector seal using new SST
Injector Seal
Injector Seal Guide
(09268-03020)
Injector Seal Holder
(09268-03010)
SST 09260-39015

Service Point (D-4 System)
Injector
Replacement of injector seals (using SST)
Needle-nosed Pliers
1. Remove injector seals
2. Attach the guide (SST)
Taper Shape

Service Point (D-4 System)
Injector
Replacement of injector seals (using SST)
3. Install a new injector
4. Slide the the injector seal into the injector groove

Service Point (D-4 System)
Injector
Replacement of injector seals (using SST)
6. Install a new injector seal
5. Settle the injector seal
Gently press

Service Point (D-4 System)
Injector
Replacement of injector seals (using SST)
8. Fully align the injector seal
7. Slide the injector seal into the injector groove

Service Point (D-4 System)
Injector
Replacement of injector seals (using SST)
10. Fully align the injector seal
9. Settle the injector seal
Gently press

Service Point (D-4 System)
Injector
Replacement of injector seals (using SST)
11. Check the injector seals
Replace

D-4 System
EDU (Electronic Driver Unit)
Drives the injectors at high speed
Engine ECU (ECM)
EDU
Injectors
High Voltage
DC / DC Converter
Command Pulse
Confirmation Pulse
Battery
IJT #1-6
IJF
Control Circuit
High-speed operation

Ignition System
Spark Plug
Long-reach type spark plug to improve cooling performance on cylinder head
Extended Water Jacket
Long-reach Type
Normal Type
Long
Iridium
Platinum

Charging System
Alternator Pulley
One-way clutch is used in the pulley to absorb engine fluctuation
One-way Clutch
Spring
Bearing
Alternator Shaft
Alternator
Alternator Pulley

Service Point (Charging System)
Alternator Pulley
Using a SST, when remove or install the alternator pulley
SST
09820-63020
(2 parts)
Remove
SST
Pulley
Shaft

Service Point (Charging System)
Alternator Pulley
Alternator pulley cap is non-reusable part
Alternator Pulley Cap
(Non-reusable Part)

Engine Control System
D-4 EFI Control (for 4GR-FSE)
D-4 EFI conducts the injection volume control and injection timing control simultaneously
Intake
Compression
Sparking
Combustion
Stoichiometric Air-fuel Ratio
(Injection)

Engine Control System
D-4 EFI Control (for 4GR-FSE)
At cold start, weak stratification combustion to improve TWC worm-up performance
Rich
Lean
Intake
Compression
Sparking
Combustion
(Injection)

Reference (Engine Control System)
D-4 EFI Control (for 4GR-FSE)
Weak stratification combustion
Creates rich and lean portions of air-fuel mixture within the combustion chamber
Injector
Plug
Piston
Rich
Lean
Injector
Plug
Piston

Engine Control System
VVT Sensor
4 MRE type VVT sensors are used for intake and exhaust camshaft of each bank
Timing Rotor
MRE Type VVT Sensor (Intake)
LH Bank
MRE Type VVT Sensor (Exhaust)
RH Bank
MRE Type VVT Sensor (Exhaust)

Reference (Engine Control System)
VVT Sensor
Output signal is digital waveform
MRE Type
Pickup Coil Type
0V
0V
Magnet
MRE
Coil
Magnet
Timing Rotor

Reference (Engine Control System)
VVT Sensor
The resistance of MRE is changed by the magnetic flux direction
Magnetic Flux
Timing Rotor

Reference (Engine Control System)
VVT Sensor
Signal output at extremely low speed rotation can be ensured
MRE Type
Pickup Coil Type
Sensor
Output
Engine
Speed
Time
Sensor
Output
Engine
Speed
No Detecting
Time

Reference (Engine Control System)
VVT Sensor
By the adoption of MRE type VVT sensor, ECM can detects the sensor low input or high input malfunction
V
Sensor low input malfunction
VVT Sensor Output Voltage
0.3
4.7
Sensor high input malfunction
High
Low

Engine Control System
Dual VVT-i (Variable Valve Timing – intelligent)
VVT-i is used for intake and exhaust camshafts
Intake
Exhaust
Vane
Lock Pin
Advance
Retard
Advance
Retard
Lock Pin
Dual VVT-i for LH Bank

Reference (Engine Control System)
Dual VVT-i
Operation
At Idle, Light Load, Low Temp. and Starting
TDC
BDC
Reduce blow back to the intake side
Engine Load
Engine Speed
Operation Range

Reference (Engine Control System)
Dual VVT-i
Operation
At Medium Load
TDC
BDC
Increase internal EGR, Eliminate pumping loss
Engine Load
Engine Speed
Operation Range

Reference (Engine Control System)
Dual VVT-i
Operation
At Low/Middle speed
Heavy Load
TDC
BDC
Using the combustion pressure completely
Engine Load
Engine Speed
Operation Range
Volumetric efficiency improvement

Reference (Engine Control System)
Dual VVT-i
Operation
Engine Load
Engine Speed
At High speed
Heavy Load
Operation Range
TDC
BDC
volumetric efficiency improvement
Reduce pumping loss

Service Point (Engine Control System)
Dual VVT-i
Following 14 DTCs are added by adoption of exhaust VVT-i

Engine Control System
Cranking Hold Function
Once the power mode is turned to “Engine Starting”, starter operates until engine starting
Starter
Stop Light Switch (AT)
or
Clutch Switch (MT)
ACC Relay
IG1, 2 Relay
Engine Switch
Park Neutral Position Switch (AT)
or
Clutch Switch (MT)
STSW
ACCR
STAR
STA
1, Start signal
2, ACC power cut
Engine ECU (ECM)
Power Source Control ECU
3, Operates starter
Engine Coolant
Temp. Sensor
Crankshaft Position Sensor
Stop Light Switch
Starter Cut Relay
Starter Relay

Reference (Engine Control System)
Cranking Hold Function
Operation
Start Signal
Starter Relay
ACC Relay
NE Signal
Time
ON
Automatically Controlled
Judgment
OFF
ON
OFF
ON
OFF

Reference (Engine Control System)
Cranking Hold Function
Judgment of the engine firing
Maximum cranking time
Engine Coolant Temp. (°C)
Judgment Level (rpm)
Engine Coolant Temp. (°C)
Max. Cranking Time (sec.)
Judgment of the engine firing
Maximum cranking time
(When engine does not start by some abnormalities)

Reference (Engine Control System)
Cranking Hold Function
Protection during engine starting
1200 rpm
OFF
NE Signal
ON
Start Signal
OFF
Starter Relay
Time
Driver pushes the engine switch intentionally
If the engine speed becomes 1200 rpm or more while cranking, engine ECU (ECM) stops starter to prevent starter overrun

Reference (Engine Control System)
Cranking Hold Function
Protection during engine starting
Engine does not start (Problem)
Starter Relay
NE Signal
ON
Start Signal
OFF
Time
Driver pushes the engine switch intentionally
30 sec.
OFF
Starter overheating protection operates starter max.30 sec.
with intentional starter operation