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Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Isi Klik Pada Sub Seksi.

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Presentasi berjudul: "Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Isi Klik Pada Sub Seksi."— Transcript presentasi:

1 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Isi Klik Pada Sub Seksi

2 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Mesin Keseluruhan Kelengkapan Mesin Mekanisme Katup Sistem Pendinginan Sistem Intake dan Exhaust Sistem Bahan Bakar Sistem Pengapian Sistem Serpentine Belt Drive Engine Control System

3 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mesin Keseluruhan Garis Besar –Mesin 1TR-FE leaded gasoline, merupakan rancangan baru in-line 4-cyliner, 2.0-liter, 16-valve DOHC dengan VVT-i, chain drive

4 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mesin Keseluruhan Spesifikasi Mesin Model1TR-FE1RZ-E (KIJANG) Jumlah silinder & susunan4-cylinder, In-line  Mekanisme Katup 16-valve, DOHC with VVT-i, Chain Drive 8-valve, SOHC, Chain Drive Displacement[cm 3 (cu. in.)]1998 (121.9)  Bore x Stroke[mm (in.)]86.0 x 86.0 (3.39 x 3.39)  Compression Ratio9.8 : 19.0 : 1 Maximum Output SAE-NET[kW / rpm] 100 / 5,60071 / 4,800 Maximum Torque SAE-NET[N·m / rpm] 182 / 4, / 2,800 Valve Timing Intake Buka 0  45 BTDC13 BTDC Tutup 64  19 ABDC47 ABDC Exhaust Buka 44 BBDC53 BBDC Tutup 8 ATDC7 ATDC Fuel Octane Rating91 atau lebih  Oil Viscosity / Oil Grade 5W-30 / API SL, SJ, EC or ILSAC 

5 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mesin Keseluruhan Keseluruhan Resin Type Cylinder Head Cover Flat type knock sensor Long Nozzle 4-hole Type Injector No-contact Type Throttle Position Sensor TOYOTA Genuine Super LLC Segment Conductor Type Alternator Resin Type Intake Manifold DIS and Long Reach Type Spark Plug Stainless Steel Exhaust Manifold VVT-i System

6 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mesin Keseluruhan Informasi Identifikasi –Nomor mesin di cetak pada sisi kiri bawah blok mesin

7 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Kelengkapan Mesin Tutup Kepala Silinder –Mengurangi konsumsi oli mesin yang melalui blow-by gas, berat dan juga suaranya Resin Acrylic Rubber Baffle Plate Fresh Air Ke Intake Manifold

8 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Kelengkapan Mesin Kepala Silinder –Terbuat dari aluminum alloy ringan Aluminum Alloy 3-layer Steel Laminate 22.85° Taper Squish Hydraulic Lash Adjuster

9 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Kelengkapan Mesin Blok Silinder –Terbuat dari cast iron, memiliki sirip untuk memperkuat rigiditas dan mengurangi suara dan getaran Aluminum Alloy Cast Iron Steel

10 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Kelengkapan Mesin Piston –Dari bahan aluminum alloy, menggunakan ring piston low tension untuk mengurangi keausan Taper Squish Shape Resin Coating Alumite Treatment for Top Ring Groove [Low Tension Piston Rings] 2 Pieces Oil Ring Chrome-plated 2nd Compression Ring PVD Coated 1st Compression Ring PVD: Physical Vapor Deposition

11 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Kelengkapan Mesin Bearing Crankshaft –Bearing crankshaft yang tak memiliki kuku (claw) –Permukaan bearing micro-grooved (alur halus) [Bearing Bawah] [Bearing Atas] Micro-grooved

12 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Kelengkapan Mesin) Pemasangan Ring Piston Set –Tempatkan ring piston hingga ujung nya seperti pada gambar dibawah Front Mark No. 1 Compression Oil Ring Expander 45° No. 2 Compression

13 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Kelengkapan Mesin) Pemasangan Bearing Crankshaft Bagian Atas –Posisi bearing harus berada di tengah journal blok silinder untuk meluruskan lubangnya Lubrication Hole [Upper Bearing] [OK] [NG] Center Lubrication Hole

14 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Kelengkapan Mesin) Pemasangan Bearing Crankshaft Bagian Bawah –Bearing harus berada di tengah, ukur posisinya Vernier Caliper B C [Perbedaan antara “B” dan “C”: 0.3 mm (0.012 in.) atau kurang]

15 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Kelengkapan Mesin) Pemasangan Bearing Crankshaft –Nilai Referensi Journal Bearing AtasBearing Bawah Ukuran “A” [mm (in.)]Ukuran “B” atau “C” [mm (in.)] #1, ( )  0.1 (0.004)3.83 (0.1508)  0.1 (0.004) # ( in.)  0.1 (0.004)1.74 (0.0689)  0.1 (0.004) #2, (0.0183)  0.1 (0.004) A A Vernier Caliper B C

16 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Kelengkapan Mesin) Baut Puli Crankshaft –Baut puli crankshaft tak boleh digunakan kembali Crankshaft Pulley Set Bolt

17 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Keseluruhan –Mekanisme Katup Terdiri dari roller rocker arm, hydraulic lash adjuster dan sistem VVT-i Timing Chain Intake Valve Exhaust Valve Oil Delivery Pipe (cam dan rocker arm) VVT-i Controller Roller Rocker Arm Hydraulic Lash Adjuster

18 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Rocker Arm –Roller rocker arm dengan built-in needle bearing digunakan untuk mengurangi gesekan, sehingga memperbaiki konsumsi bahan bakar Roller Rocker Arm Oil Delivery Pipe Needle Bearing [Roller Rocker Arm]

19 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Hydraulic Lash Adjuster –Mempertahankan celah katup nol dengan menggunakan tekanan oli dan tegangan pegas Plunger Oil Passage Check Ball Spring Check Ball Plunger Spring Low Pressure Chamber High Pressure Chamber Zero Valve Clearance Oil Passage

20 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Reference (Mekanisme Katup) Roller Rocker Arm dan Hydraulic Lash Adjuster Oil Passage

21 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Hydraulic Lash Adjuster –Awal penekanan katup, tekanan tinggi dari high pressure chamber didapat dari tekanan plunger High Pressure Chamber Plunger

22 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Hydraulic Lash Adjuster –Kemudian rocker arm membuka katup dengan menggunakan hydraulic lash adjuster sebagai tumpuan High Pressure Chamber Fixed Plunger Tumpuan

23 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup High Pressure Chamber Body Hydraulic Lash Adjuster –Cam naik, plunger diangkat oleh plunger spring, check valve terbuka, dan oli terisi. Check Ball Plunger

24 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Hydraulic Lash Adjuster –Plunger diangkat oleh tekanan pegas. Sehingga celah katup tetap nol Zero Valve Clearance Plunger Spring Plunger

25 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Mekanisme Katup Hydraulic Lash Adjuster –Cara Kerja

26 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Mekanisme Katup) Hydraulic Lash Adjuster –Prosedur penggantian oli 1. Tekan check ball ke bawah dengan SST Hydraulic Lash Adjuster [SST: ] Benar Salah SST

27 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Mekanisme Katup) Hydraulic Lash Adjuster –Prosedur penggantian oli 2. Masukkan hydraulic lash adjuster pada oli mesin bersih, tekan adjuster dengan SST untuk menggerakan plunger naik turun kali Clean Engine Oil

28 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Mekanisme Katup) Hydraulic Lash Adjuster –Prosedur penggatian oli 3. Plunger akan keras ketika plunger ditekan kuat dengan tangan

29 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Mekanisme Katup) Hydraulic Lash Adjuster –Prosedur penggantian oli Ganti dengan yang baru, jika plunger bisa bergerak walau olinya sudah diganti 3 kali

30 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Mekanisme Katup) Timing Chain –Pasang rantai pada sprockets dengan bagian yang dicat lurus terhadap tanda timing Crankshaft: No1. TDC Yellow Paint Timing mark Orange Paint Timing mark Chain Tensioner Key

31 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Pendinginan Pendingin Mesin Tipe pendingin mesin TOYOTA Genuine Super Long Life Coolant (SLLC) atau sejenis Kapasitas [liters (US qts, Imp. qts)]7.0 (7.4, 6.2) Jarak Maintenance PemeriksaanSetiap 40,000 km (25,000 miles) Penggantian Pertama160,000 km (100,000 miles) BerikutnyaSetiap 80,000 km (50,000 miles)

32 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Intake dan Exhaust Keseluruhan Resin Type Intake Manifold Link-less Type Throttle Body Stainless Steel Exhaust Manifold Sub Muffler Main Muffler

33 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Bahan Bakar Keseluruhan –Digunakan injector nozzle panjang dan quick connector Long Nozzle 4-hole Type Injector Pulsation Damper Pressure Regulator Fuel Filter Quick Connector

34 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Bahan Bakar Injector –Injector nozzle panjang digunakan untuk mengurangi emisi gas buang dengan mencegah bahan bakar menempel pada dinding intake Approx mm Long Nozzle TypeNormal Type* *Normal Type: 8.8 mm

35 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Bahan Bakar Keseluruhan Quick Turn Construction Fuel Cap Steel Tank (55 L) [Fuel Pump Module] [Quick Connector] Fuel Sender Gauge Pump Motor Fuel Filter

36 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Pengapian Keseluruhan –DIS menggunakan 4 ignition coils (4 silinder) –Digunakan busi tipe panjang DIS Long Reach Type Spark Plug Normal Type Spark Plug

37 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Pengapian Busi –Busi panjang memperbaiki sistem pendinginan pada kepala silinder (water jacket) Extended water Jacket Long-reach TypeNormal Type Long Center Electrode: Normal type

38 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Pengapian Busi –Spesifikasi Busi SupplierDENSOK20HR-U11 Jangkauan [Ref.: Tipe Normal]Sekitar 26.5 mm [19.0 mm] Celah Busi mm Jarak PenggantianSetiap 20,000 km atau 24 Bulan

39 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Serpentine Belt Drive Keseluruhan –Komponen asesories digerakan oleh serpentine belt, single V type 7-ribbed belt Power Steering Pump Pulley Water Pump Pulley Air Conditioner Compressor Pulley Alternator Pulley Automatic Tensioner Crankshaft Pulley Idler Pulley No. 2 Idler Pulley No. 1

40 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Sistem Serpentine Belt Drive Variasi Serpentine Belt berikutnyaSetiap km [Jarak Pemeriksaan Serpentine Belt]

41 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System Keseluruhan Camshaft Position Sensor Water Temp. Sensor Air Flow Meter Flat Type Knock Sensor Non-contact Type Throttle Position Sensor [Lainnya] 32-bit Engine ECU Non-contact Type Accelerator Pedal Position Sensor Ignition Coil with Igniter Crankshaft Position Sensor

42 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Engine Control System Flat type knock sensor –Built-in open circuit detection resistor pada flat knock sensor Resistor NOTE:Saat open circuit, muncul DTC P0325 (baru) Piezoelectric Element Resistor 2.5 V 5 V

43 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Service Point (Engine Control System) Flat type knock sensor –Pasang knock sensor pada sudut tertentu (10°) Depan 10

44 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i (Electronic Throttle Control System-intelligent) –Link-less type ETCS-i, untuk pengontrolan throttle yang lebih baik (Non-linear control/Idle speed control) Accelerator Pedal Position Sensor Throttle Position Sensor Throttle Control Motor Engine ECU Ignition Coil Fuel Injector Air Flow Meter

45 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –No-contact type throttle position sensor Throttle Position Sensor Throttle Control Motor Reduction Gears Throttle Valve Hall ICs Magnets

46 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Reference (Engine Control System) ETCS-i –2 Hall ICs dan 2 magnets digunakan untuk throttle position sensor Throttle Valve Hall ICs Magnets

47 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –Throttle position sensor merubah densitas magnetic flux menjadi electric signal Throttle Valve Opening Angle Full OpenFull Close VTA1 VTA2 Output Voltage (V) 0 5 ECM VTA1 VTA2 E2 VC Throttle Valve Opening Angle Full OpenFull Close VTA VTA2 Output Voltage (V) 0 5 Engine ECU VTA VTA2 E2 VC Hall IC Magnet

48 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –No-contact type Accelerator pedal position sensor Accelerator Pedal Arm Hall ICs Magnets

49 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –Accelerator pedal position sensor merubah densitas magnetic flux menjadi electric signal Accelerator Pedal Depressed Angle Full OpenFull Close VPA VPA2 Output Voltage (V) 0 5 VPA VPA2 EPA2 EPA Hall ICs Magnets VCPA VCP2 Engine ECU (ECM)

50 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –Fail-safe jika malafungsi pada accelerator pedal position sensor Accelerator Pedal Position Sensor Throttle Position Sensor Throttle Control Motor [Normal Condition] Idle Full Engine ECU [Single Signal Failure] Idle Engine ECU [Double Signal Failure] Idle Engine ECU

51 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –Fail-safe jika malafungsi pada throttle valve position sensor / motor / engine ECU / wire harness [Fail-safe] Accelerator Pedal Position Sensor Throttle Position Sensor [Normal Condition] Idle Full Engine ECU Throttle Control Motor Idle Fixed (6.5) Engine ECU

52 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System ETCS-i –Fail-safe jika malafungsi pada throttle valve position sensor / motor / engine ECU / wire harness [Full Acceleration][Idling] Idle Fixed Engine ECU Retard4 >> 2 Cylinder Idle Fixed Engine ECU Normal2 >> 4 Cylinder

53 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System VVT-i (Variable Valve Timing-intelligent) System –VVT-i system di rancang untuk mengontrol intake camshaft sehingga menghasilkan valve timing yang sesuai dengan kondisi mesin Crankshaft Position Sensor VVT-i Controller Camshaft Timing Oil Control Valve Water Temp. Sensor Camshaft Position Sensor Throttle Position Sensor Air Flow Meter Engine ECU

54 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System VVT-i System –Controller terdiri dari housing yang digerakkan timing chain dan vane yang bersatu dengan intake camshaft Oil Pressure [In Operation] Lock Pin Housing Vane (Fixed on Intake Camshaft) Timing Rotor SprocketIntake Camshaft [At a Stop]

55 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System VVT-i System –Camshaft timing oil control valve mengontrol posisi spool valve sesuai dengan duty control dari ECU mesin Plunger Coil Oil Pressure Spool Valve Drain To VVT-i Controller (Advanced Side) (Retard Side) Engine ECU

56 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Fitur Mesin 2TR-FE Spesifikasi Mesin 2TR-FE Model1TR-FE2TR-FE Jumlah silinder & susunan4-cylinder, In-line  Mekanisme Katup 16-valve, DOHC with VVT-i, Chain Drive  Displacement [cm 3 (cu. in.)]1,998 (121.9)2,694 (164.4) Bore x Stroke [mm (in.)]86.0 x 86.0 (3.39 x 3.39)95.0 x 95.0 (3.74 x 3.74) Rasio Kompresi9.8 : 1  Maximum Output SAE-NET [kW / rpm] 100 / 5, / 5,200 Maximum Torque SAE-NET [N·m / rpm] 182 / 4, / 3,800 Valve Timing Intake Buka 0  45 BTDC Tutup 64  19 ABDC Exhaust Buka 44 BBDC Tutup 8 ATDC Fuel Octane Rating91 atau lebih  Tailpipe Emission Regulation  EURO II Oil Viscosity / Oil Grade 5W-30 / API SJ, SL, EC atau ILSAC 

57 Model OutlineChassisBodyBody ElectricalMesin 1TR-FE Fitur Mesin 2TR-FE Perbedaan Utama dari Mesin 1TR-FE 1TR-FE2TR-FE Balance shaft  2 balance shafts TWC  with Fuel TankSteelResin InjectorLong nozzle 4-hole typeLong nozzle 12-hole type StarterP1.0PS1.6 A/F, O 2 Sensor  Planar type O 2 with heater x 1

58 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Engine Control System Fuel Pump Control –Signal peledakan airbag dari airbag sensor assembly dideteksi oleh ECU mesin, lalu meng-OFF circuit opening relay M Fuel Pump Motor EFI RelayIgnition Switch Engine ECU Front Airbag Sensors (LH or RH) Airbag Sensor Assembly GSW2 F/PS Airbag not deployed Airbag deployed Approx. 4 sec. Battery Voltage Circuit Opening Relay

59 ChassisBodyBody ElectricalModel OutlineMesin 1TR-FE Fitur Lain Sistem Pengisian –Segment Conductor type alternator yang kompak dan ringan Motor Starter –Conventional planetary reduction type starter TipeSE08 Rated Voltage / Output12V / 80A SupplierDENSO TipeP1.0 Rated Voltage / Output12V / 1.0 kW SupplierDENSO


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