Outline Fuel System of Conventional EFI-diesel

In the conventional EFI-diesel, control of injection timing

Fuel filter, sedimenter SPV (injection volume control) and volume is performed electronically. The device that
generates the fuel pressure is the same pump used in an
ordinary diesel engine.
HINT:
The fuel return circuit from the injection nozzle or
injection pump is not illustrated at left, but the fuel
TCV return circuit is attached to the actual fuel system.
(Injection timing control)
(1/2)

Fuel tank
Injection nozzle

The fuel that is drawn up by the feed pump travels from

Fuel filter, sedimenter SPV (injection volume control) the fuel tank through the fuel filter, and is introduced into
the pump where it becomes pressurized and then
pumped by the plunger inside of the injection pump. This
process is the same as in an ordinary diesel pump. The
fuel in the pump chamber becomes pressurized by the
feed pump so that it is between 1.5 and 2.0 MPa. Further-
TCV
more, in accordance with the signals from the ECU, the
(Injection timing control) SPV controls the injection volume (injection duration) and
the TCV controls the fuel injection timing (injection start-
ing timing).
Fuel tank
Injection nozzle HINT:
The fuel return circuit from the injection nozzle or
injection pump is not illustrated at left, but the fuel
return circuit is attached to the actual fuel system.
(2/2)

Axial plunger type pump
Type of Pump
A conventional EFI-diesel uses one of the two types of
Radial plunger type pump
distributor pump: an axial plunger type pump, and a radial
plunger type pump with a higher injection pressure.

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 • Internal construction of axial plunger type pump
SPV (Spill Control Valve)

Speed sensor

Feed pump

Roller ring

Rotor Plungers
Cam plate TCV (Timing Control Valve)

• Internal construction radial plunger type pump

SPV (Spill Control Valve) Speed sensor (1/1)

Feed pump
Rotor

Rollers

Plungers

TCV (Timing Control Valve) Cam ring

REFERENCE
Injection Pressure for Each Type of Pump

Axial Plunger Type Pump

Approx. 80 MPa maximum
(used on 5L-E 1KZ-TE, etc.)

Radial Plunger Type Pump

Approx. 130 MPa maximum
(used on direct-injection engines such as 1HD-FTE, 15B-FTE, etc.)

(1/1)

Pump Construction of Pump Portion of Axial Plunger Type

Pump
The pump consists of the following:

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 • Roller ring

• Rollers

• Cam plate

• Plungers
(1/1)

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 Operation of Pump Portion of Axail Plunger Type
Pump
(1/1)

Construction of Pump Portion of Radial Plunger Type

Pump
The pump consists of the following:

• Cam ring

• 4 rollers

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 • 4 plungers
(1/1)

REFERENCE
Pump for 6-Cylinder Type
(1/1)

Pump for 4-cylinder type Pump for 6-cylinder type

Operation of Pump Portion of Radial Plunger Type

Pump
(1/1)

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Injection Volume Outline of SPV
There are two types of SPV (Spill Control Valve) that con-
Conventional type SPV Direct-acting type SPV
trol the injection volume.
• Conventional type SPV
(used in axail plunger type pump)
• Direct-acting type SPV
(used in the radial plunger type pump for high-pres-
sure applications)
(1/1)

Conventional Type SPV

Coil Pilot valve 1. Construction
The conventional type SPV consists of two valves:
Pilot spring
main valve and pilot valve.
(1/2)

Main spring Main valve

2. Operation
• At normal condition
The pilot valve of the SPV is normally closed, as elec-
tricity runs through the coil. The fuel pressure and the
spring force causes the main valve to close passage
"A" as well, due to the pressure from the inside of the
valve being greater than that of the outside of the
valve.
• When the signal from the engine ECU is turned off
When the signal from the ECU turns off, causing the
current applied to the coil to turn off, the pilot valve
moves upward by the force of the pilot spring, causing
passage "B" to open.
• When the pilot valve is opened
Then, the pressure that is applied above the main
valve decreases. As a result, the main valve ascends,
causing passage "A" to open.
(2/2)

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 Direct-acting Type SPV
1. Construction
Coil In contrast to the conventional type SPV, the direct-acting
type SPV, which is fitted in a pump with a higher fuel pres-
sure, achieves high levels of response and spill charac-
Spool valve teristics.
ECU
Furthermore, the signals from the ECU are amplified by
the EDU to operate the valve at a high voltage of approxi-
ECU
Spring mately 150V when closing the valve. Thereafter, the valve
remains closed at a low voltage.
(1/2)

2. Operation
• At normal condition
The spool valve is pulled downward to close the pas-
sage because the coil is energized.
• When the current does not flow into the coil
When the current to the coil is turned off, the pressure
of the fuel pushes the spool valve upward to open the
passage.
(2/2)

REFERENCE
(v) Starting Voltage of Direct-acting SPV
When the direct-acting type SPV starts to operate,
approximately 150V are applied to the coil. Thereafter,
150 duty-cycle control is effected at a lower voltage.
(1/1)

Time

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 Operation of Pump and SPV
Axial plunger type pump
There are two types of plungers:
• Axial plunger type pump
• Radial plunger type pump
(1/1)

Radial plunger type pump

Axial plunger Type Pump and SPV

Operation
• Intake stroke
SPV closes.
Plunger moves left.
Fuel is drawn into chamber.
• Injection
SPV closes.
Plunger moves right.
Fuel pressure rises and fuel is pumped.
• Injection ends
SPV opens.
Due to fuel relief, pressure decreases.
Injection ends.

When the conditions for fuel cut-off have been met,

the pressure does not increase because the SPV
remains constantly open.
(1/1)

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 Radial Plunger Type Pump and SPV
Operation
• Intake stroke
SPV opens.
Rollers and plungers expand outward, drawing fuel
into the chamber.
• Pressure rises
SPV closes.
Rollers and plungers contract, causing pressure to
rise.
• Injection
SPV closes.
Rotor rotates and connects the rotor's pumping port
and distribution port, allowing the fuel to be pumped.
• Injection ends
SPV opens.
Due to fuel relief, pressure decreases.
Injection ends.

When the conditions for fuel cut-off have been met,

the pressure does not increase because the SPV
remains constantly open.
(1/1)

Injection Volume Adjustment

The injection volume is adjusted by
Start of injection operating the SPV in accordance with
the signals from the ECU to vary the tim-
Plunger
ing of the ending of the injection.
(1/1)

Close

SPV

Open

Decrease Initial condition

d o Increase

Injection Timing Construction of TCV (Timing Control Valve)

The construction of the timing control valve is shown in
Coil the illustration in the left.
(1/2)

Moving core Spring

Stator core

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 The construction of the timer is shown in the illustration in
the left.
(2/2)

Roller ring

Timer piston TCV (Timing Control Valve)

Operation of Timer of Axial Plunger Type Pump

The TCV valve is controlled by the ratio (duty-cycle ratio)
of the ON/OFF time of the current that is applied to the
coil. The length of time that the valve remains open, with
the current ON, controls the fuel pressure in the timer pis-
ton.
Advance
When the length of time that the valve remains open is
short (the ratio of the current being applied is low), the
amount of fuel that is bypassed becomes smaller. Thus,
the timer piston moves to the left to rotate the roller ring in
the direction of timing advance.
Retard
When the length of time that the valve remains open is
long (the ratio of the current being applied is high), the
amount of fuel that is bypassed becomes greater. Thus,
the timer piston moves to the right by the force of the
spring to rotate the roller ring in the direction of timing
retard.
(1/1)

Operation of Timer of Radial Plunger Type Pump

The TCV valve is controlled by the ratio (duty-cycle ratio)
of the ON/OFF time of the current that is applied to the
coil. The length of time that the valve remains open, with
the current ON, controls the fuel pressure in the timer pis-
ton.
Advance
When the length of time that the valve remains open is
short (the ratio of the current being applied is low), the
amount of fuel that is bypassed becomes smaller. Thus,
the timer piston moves to the left to rotate the roller ring in
the direction of timing advance.
Retard
When the length of time that the valve remains open is
long (the ratio of the current being applied is high), the
amount of fuel that is bypassed becomes greater. Thus,
the timer piston moves to the right by the force of the
spring to rotate the roller ring in the direction of timing
retard.
(1/1)

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Service Hint Injection Pump Installation
Install the injection pump by aligning the matching mark
on the injection pump with the reference position mark on
the engine.
Because the ECU recognizes the injection timing and
makes appropriate corrections, it is not necessary to
adjust the injection timing after assembly, as with the
mechanical diesel pump.
(1/1)

SPV Inspection
Inspect the SPV by removing the connector and measur-
ing the resistance between the SPV terminals.
(1/1)

TCV Inspection
Inspect the TCV coil by removing the connector and mea-
suring the resistance between the TCV terminals.

- 11 -
 Inspect the operation of the TCV by connecting the posi-
tive (+) and negative (-) terminals of the battery to the
TCV terminals and checking the clicking sound of the
solenoid.
(1/1)

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Exercise

These are the pre-course study materials for the Frequent Service Job Course. The objective of this course
is to learn the work procedure and points of frequent service jobs. In the pre-course study, you will study the
basic knowledge needed for repair work, and the basic mechanism and operation of automobiles. After you
finish studying all of the chapters, please take the Examination.

Chapter All Next Chapter All

Answers Answers
Correct Correct
Page with Exercises Page with Exercises
Related Text Related Text
Incorrect Incorrect
Answer Answer

Return to page of Return to page of

related text for review related text for review

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Question- 1
The following illustration shows the axial plunger type injection pump.
From the word group, select the part to perform the following controls (1-4).

1. Pumps the fuel from fuel tank.

2. Pumps and distributes the fuel.
3. Controls the injection volume.
4. Controls the injection timing.

a) Feed Pump
g
b) Speed Sensor
b c) Rotor
d) Roller Rin
e) Cam Plate
f) TCV
a
g) SPV
d h) Plunger
c h
e
f

Answer: 1. 2. 3. 4.

Question- 2
The following illustration shows the radial plunger type injection pump.
From the word group, select the part to perform the following controls (1-4).

1. Pumps the high pressure fuel.

2. Distributes the fuel.
3. Controls the injection volume.
4. Controls the injection timing.

a) Feed Pump
g b b) Speed Sensor
c) Cam ring
d) Roller
f a e) Plunger
f) Rotor
g) SPV
d h) TCV
e
c
h

Answer: 1. 2. 3. 4.

- 14 -
Question- 3
Mark each of the following statements True or False.

No. Question True or False Correct Answers

The axial plunger type injection pump used in the conventional EFI-
1 diesel uses a greater injection pressure than the radial plunger type True False
injection pump.

The axial plunger type injection pump and the radial plunger type
injection pump (both used in the conventional EFI-diesel) have the
2 True False
same fuel pressurizing and distribution systems.
However, their injection volume and timing controls differ.

Question- 4
The following illustrations show the SPV. From the word group, select the words that correspond to 1-4 in the table.

Name (1)

Application for High injection pressure pump

Operating voltage (2)

Name (3)

Application for Ordinary pump

Operating voltage (4)

a) Direct-acting type SPV b) Conventional SPV c) Normal voltage d) High voltage

Answer: 1. 2. 3. 4.

Question- 5
Mark each of the following statements True or False.

No. Question True or False Correct Answers

When the power is turned ON to the SPV, the fuel passage opens
1 True False
and the injection ends.

The SPV controls the relief timing of the fuel that has been pressur-
2 True False
ized by the plunger in order to regulate the injection volume.

The TCV regulates the operating stroke of the plunger in order to

3 True False
regulate the injection start timing.

The ECU activates the TCV and controls the amount of the pressur-
4 ized fuel that is applied to the timer piston in order to regulate the True False
injection timing.

- 15 -
Question- 6
Mark each of the following statements True or False.

No. Question True or False Correct Answers

The inspection of the coils for the SPV and the TCV is performed by
1 True False
measuring the resistance between the terminals.

To reinstall the injection pump of the conventional EFI-diesel on the

2 engine, the injection timing must be adjusted just as with the True False
mechanical diesel pump.

- 16 -