EG Mechanical

EG-112

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

1KD-FTV AND 2KD-FTV ENGINES  DESCRIPTION  

1KD-FTV TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine) and 2KD-FTV TOYOTA D-4D are 3.0/2.5 liter, in-line 4-cylinder, 16-valve DOHC with turbocharged diesel engine.  These engines uses direct injection system and common-rail system to realize higher performance, clean emission, low noise and low vibration.  A 2KD-FTV High Version, which has a higher power output than the normal 2KD-FTV engine, is also available. The 2KD-FTV and 2KD-FTV High Version engines are equipped with engine ECUs containing engine control programs that differ from each other. However, both engine models share the same mechanical components.  An intercooler is provided on all 1KD-FTV engine models and the 2KD-FTV High Version engine for Thailand. This lowers the intake air temperature and improves power output.  The basic construction and operation of both the 1KD-FTV and 2KD-FTV engines are the same. For details, see "Major Difference" on page EG-114. 1KD-FTV Engine

271EG97

2KD-FTV Engine without Inter Cooler 

271EG98

EG-113

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES Engine Specifications

1KD-FTV

2KD-FTV

2KD-FTV High Version

 No. of Cyls. & Arrangement Arrangement

4-Cylinder, In-line





Valve Mechanism

16-Valve 16-Valve DOHC, Belt & Gear Drive





Direct Injection Injectio n Type





Cross-flow





Common-Rail Type





Engine Type

Combustion Combusti on Chamber Manifolds Fuel System Displacement

cm3 (cu. in.)

2,982 (182.0)

2,494 (152.2)



Bore  Stroke

mm (in.)

96.0  103.0 (3.78  4.06)

92.0  93.8 (3.62  3.69)



17.9 : 1

18.5 : 1



120 kW @ 3,400 rpm

75 kW @ 3,600 rpm

Compression Ratio Max. Output

Max. Torque

[SAE-NET]

Valve Timing Exhaust

343 Nm @ 1,400 ~ 3,200 rpm

200 Nm @ 1,400 ~ 3,200 rpm

Open

2 BTDC





Close

37 ABDC

31 ABDC



Open

45 BBDC

30 BBDC



Close

0 ATDC  ATDC





1-3-4-2





50 or higher





CF-4, 10W-30





EURO III*2

EURO III*5

EURO III*8

EURO I*3

EURO I*6

EURO I*9

Firing Order Fuel Cetan Number Oil Grade

Emission Regulation

Tier 1*4 Engine Engine Service Service Mass* Mass* (Reference) (lb)

88 kW @ 3,600 rpm*5 260 Nm @ 1,600 ~ 2,400 rpm 320 Nm @ 2,000 rpm*5

[SAE-NET]

Intake

75 kW @ 3,600 rpm

kg

260 (573)

7

  *

223 (492)

10

  *

222 (489)

*1: Weight Weight shows the figure with the oil and water fully filled. 2 * : for Thai, Australian, Australian, and Central and South American American Models 3 * : for Philippine, and Central and South American American Models (only for export package models) 4 * : for Central and South American Models (only for Brazilian-spec Brazilian-spec models) 5 * : for Thai Models *6: for Philippine Models *7: for General Countries Models *8: for Thai, and Central and South American American Models 9 * : for Malaysian Models *10: for General Countries, and Central and South American American Models (only for export package models)

EG-113

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES Engine Specifications

1KD-FTV

2KD-FTV

2KD-FTV High Version

 No. of Cyls. & Arrangement Arrangement

4-Cylinder, In-line





Valve Mechanism

16-Valve 16-Valve DOHC, Belt & Gear Drive





Direct Injection Injectio n Type





Cross-flow





Common-Rail Type





Engine Type

Combustion Combusti on Chamber Manifolds Fuel System Displacement

cm3 (cu. in.)

2,982 (182.0)

2,494 (152.2)



Bore  Stroke

mm (in.)

96.0  103.0 (3.78  4.06)

92.0  93.8 (3.62  3.69)



17.9 : 1

18.5 : 1



120 kW @ 3,400 rpm

75 kW @ 3,600 rpm

Compression Ratio Max. Output

Max. Torque

[SAE-NET]

Valve Timing Exhaust

343 Nm @ 1,400 ~ 3,200 rpm

200 Nm @ 1,400 ~ 3,200 rpm

Open

2 BTDC





Close

37 ABDC

31 ABDC



Open

45 BBDC

30 BBDC



Close

0 ATDC  ATDC





1-3-4-2





50 or higher





CF-4, 10W-30





EURO III*2

EURO III*5

EURO III*8

EURO I*3

EURO I*6

EURO I*9

Firing Order Fuel Cetan Number Oil Grade

Emission Regulation

Tier 1*4 Engine Engine Service Service Mass* Mass* (Reference) (lb)

88 kW @ 3,600 rpm*5 260 Nm @ 1,600 ~ 2,400 rpm 320 Nm @ 2,000 rpm*5

[SAE-NET]

Intake

75 kW @ 3,600 rpm

kg

260 (573)

7

  *

223 (492)

10

  *

222 (489)

*1: Weight Weight shows the figure with the oil and water fully filled. 2 * : for Thai, Australian, Australian, and Central and South American American Models 3 * : for Philippine, and Central and South American American Models (only for export package models) 4 * : for Central and South American Models (only for Brazilian-spec Brazilian-spec models) 5 * : for Thai Models *6: for Philippine Models *7: for General Countries Models *8: for Thai, and Central and South American American Models 9 * : for Malaysian Models *10: for General Countries, and Central and South American American Models (only for export package models)

EG-114  MAJOR

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

DIFFERENCE

The table below lists the major differences between the 1KD-FTV and 2KD-FTV engines.

Item

1KD -FTV

2KD -FTV

2KD -FTV High Version

A SIRM (Sintered Iron Reinforced Material) ring carrier is used in the top ring groove of the t he piston.



  

  

The piston skirt has been coated with resin.



  

  

  







*

*

2 balance shafts are used.



  

  

A swirl control valve is used



  

  

A variable nozzle vane type turbocharger is used.



  

  

Air cooled type turbocharger is used.

  





An inter cooler is used.



  

*

An oxidation catalytic converter is used.

*

*

*

Fuel System

Fuel cooler is used.



  

*

Charging System

A segment conductor type alternator is used.

*

4



*

Starting System

Planetary reduction type with interpolar interpolar magnet magnet is used.

*

5

  

*

An EGR valve position sensor is used.

  

*

*

An air flow meter is used.



  

  

Swirl control system is used.



  

  

Turbocharger control system is used.



  

  

Section

Engine Proper

Intake and Exhaust System

Engine Control System

An Ni-resist cast iron ring carrier is used in the top ring groove of the piston. A PVD (Physical Vapor Deposition) coating has been applied on the surface of the No. 1 compression ring

*1: Only for emission regulation non-compliance models *2: Only for Thai Models *3: Only for EURO III or Tier 1 Compliance Models *4: except Central and South American American Models 5 * : Only for Central and South American American Models 6 * : Only for Models with EGR System

1

3

1

2

3

2 2 4

5

6

6

EG-115

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES  FEATURES

OF 1KD-FTV AND 2KD-FTV ENGINES

The 1KD-FTV and 2KD-FTV engines have achieved the following performance through the adoption of the items listed below. (1) (2) (3) (4) (5)

High performance and reliability Low noise and vibration Lightweight and compact design Good serviceability Clean emission and fuel economy Item

Engine Proper

(2)

(3)

A cylinder head cover made of plastic is used.





2 balance shaft is used.



Piston provided with combustion chamber is used in conjunction with the adoption of direct injection.

(1)



Intake and Exhaust System





A shim-less type valve lifter is used.



A pressurized reservoir tank is used.



An intake shutter valve (throttle valve), which is actuated by a torque motor (rotary solenoid type), and an airflow meter are used.







Swirl control valve is used.







A variable nozzle vane type turbocharger is used.





 

Air cooled type turbocharger is used. An inter cooler is used.



 

Oxidation catalytic converter is used.

Fuel System

HP3 type supply pump is used.







A common rail type fuel injection system is used.





Injector is provided in the bore center.





Compensation value and QR code printed injector is used.





Fuel cooler has been adopted.





A fuel filter, in which the fuel filter element alone can be replaced, has been adopted. A fuel filter warning switch that detects the clogging of the fuel filter has been adopted. Charging System

A segment conductor type alternator is used.

Starting System

Planetary reduction type with interpolar magnet is used.

  

  

An EGR valve position sensor is used. Engine Control System

(5)



The passage for the EGR is provided in the cylinder head. Valve Mechanism Cooling System

(4)

The no-contact sensor is used in the accelerator pedal  position sensor and intake shutter valve position sensor. A pilot injection control system is used.

 





EG-116 

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

ENGINE PROPER

1. Cylinder Head Cover   The

cylinder head cover is made of plastic to reduce weight and noise.   A baffle plate is provided on the inside of the cylinder head cover to reduce the consumption of engine oil through blow-by gas.

A

A

Baffle Plate

271EG99

A-A Cross Section

2. Cylinder Head Gasket  A

steel-laminate type cylinder head gasket has been adopted.  A shim has been added around the cylinder bore to increase the sealing surface, thus realizing excellent sealing performance

A Shim A

Front

Cylinder Bore Side A –  A Cross Section

Outer Side 271EG100

Service Tip

There are 5 sizes of new cylinder head gaskets, marked A , B , C , D , or E  according to  piston protrusion. For details, refer to Hilux Repair Manual. “

”

“

”

“

”

“

”

“

”

A B C Rear D E

271EG101

EG-117

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

3. Cylinder Head The cylinder head is made of aluminum alloy. The injector has been located in the center of the combustion chamber in order to improve engine performance and clean emission.  Two intake ports with different shapes have been combined to promote the mixture of fuel and air by optimizing the swirl in the cylinder.  A vertical two-stage construction is used for the water jacket to improve cooling performance.  A glow plug is placed between the intake ports of each cylinder to ensure startability.   The passage for the EGR is provided in the cylinder head. By cooling the exhaust gas, this makes it  possible to re-circulate the great amount of exhaust gas.  The cylinder head bolt employs plastic region tightening bolts. 

Injector Hole

EX

IN

EGR Passage

EX

IN

EX

IN

EX

IN

Water Jacket

Glow Plug Hole

195EG41

195EG42

4. Cylinder Block The cylinder block is constructed of liner-less cast iron alloy.  A rib has been added to the block of the cylinder block to reduce engine vibration. 

Rib

271EG102

EG-118

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

5. Balance Shaft (for 1KD-FTV Engine)  For

in-line 4 cylinder engines, the main cause of vibration is imbalanced inertial force of reciprocating  parts such as the pistons and connecting rods. The 1KD-FTV engine vibration has been reduced by using 2 balance shafts to cancel the imbalanced inertial force, thereby reducing engine noise (booming noise).  These balance shafts are built into the cylinder block. Driven by the timing gear, the balance shafts rotate at twice the speed of the crankshaft and in the opposite direction of each other.

Balance shaft No.1 Supply Pump Drive Gear Oil Pump Drive Gear

Crankshaft Timing Gear Balance Shaft No.2 Idle Gear

195EG47

6. Piston In conjunction with the adoption of direct injection, piston provided with combustion chamber is used.  The piston is made of aluminum alloy.  A cooling channel has been provided to reduce the piston temperature.   To improve the wear resistance of the top ring groove, the 1KD-FTV engine has adopted an SIRM (Sintered Iron Reinforced Metal) ring carrier and the 2KD-FTV engine has adopted an Ni-resist cast iron ring carrier.   On 1KD-FTV engine models and emission regulation non-compliance 2KD-FTV engine models, a PVD (Physical Vapor Deposition) coating has been applied to the surface of the No.1 compression ring, to improve its wear resistance.  The piston skirt portion of the 1KD-FTV engine has been coated with resin to reduce the friction loss. 

 Ni-resist Cast Iron Ring Carrier

SIRM Ring Carrier

Resin Coating

Cooling Channel 1KD-FTV Engine

271EG103

Cooling Channel 2KD-FTV Engine

271EG159

EG-119

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

7. Connecting Rod and Connecting Rod Bearing  The

connecting rods are made of high-strength material to ensure the proper strength.  Knock pins are used at the mating surfaces of the bearing caps of the connecting rod to minimize the shifting of the bearing caps during assembly.  Plastic region tightening bolts are used.  An aluminum bearing is used for the connecting rod bearings.

Knock Pin

271EG104

Plastic Region Tightening Bolt

8. Crankshaft and Crankshaft Bearing  The

crankshaft has 5 journals and 8 balance weights.  All pin and journal fillets are roll-finished to maintain adequate strength.  The crankshaft bearing is made of aluminum alloy.  The lining surface of the crankshaft bearing has been micro-grooved to realize an optimal amount of oil clearance. As a result, cold-engine cranking performance has been improved and engine vibrations have  been reduced.  The upper main bearing has an oil groove around its inside circumference. Roll-Finished Upper Main Bearing Oil Hole

Oil Grooved

Micro-Grooved

Lower Main Bearing

271EG105

EG-120

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

9. Crankshaft Pulley The rigidity of the torsional damper rubber has  been optimized to reduce noise.

Torsional Damper Rubber

271EG106

EG-121

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES 

VALVE MECHANISM

1. General   Each

cylinder has 2 intake valves and 2 exhaust valves. Intake and exhaust efficiency is increased by means of the larger total port areas.  The valves are directly opened and closed by 2 camshafts.  The intake camshaft is driven by a timing belt, while t he exhaust camshaft is driven through gear on the intake camshaft.  Small-diameter, and flat-teeth gears are used for driving the exhaust camshaft in order to reduce gear  noise.

Gears

Exhaust Camshaft

Intake Camshaft Timing Belt

271EG107

EG-122

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

2. Camshaft The cam nose has been chill treated to increase its abrasion resistance.

: Chill Treated

Exhaust Camshaft Camshaft Drive Gear

Intake Camshaft Camshaft Drive Gear 224EG08

3. Intake and Exhaust Valves  Along

with the increased amount of valve lift, shim-less valve lifters that provide a large cam contact surface have been adopted.  The adjustment of the valve clearance is accomplished by selecting and replacing the appropriate valve lifters. Camshaft

Valve Lifter

208EG69

Service Tip

The valve lifters must be replaced when it is necessary to adjust the valve clearance. For this  purpose, valve lifters with different thickness are available as service parts. For details, refer to the Hilux Repair Manual.

EG-123

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

4. Timing Gear Train  The

supply pump, vacuum pump, oil pump and balance shafts* are driven by the crankshaft timing

gear.  The idle gear is constructed with a scissors gear on its front and back to reduce noise.

Camshaft Timing Pulley No.1

Balance Shaft Drive Gear* Oil Pump Drive Gear

Supply Pump Drive Gear

Automatic Tensioner

Camshaft Timing Pulley No.1

*: Only for 1KD-FTV Engine

Vacuum Pump Drive Gear Crankshaft Timing Gear

Idle Gear

271EG161

EG-124 

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

LUBRICATION SYSTEM

1. General  The

lubrication circuit is fully pressurized and all oil passes through an oil cooler and oil filter.  A trochoid oil pump driven by a gear engaged with the crankshaft is used.  A water-cooled type engine oil cooler is enclosed in the cylinder block.  Piston oil jets that lubricate and cool the piston are provided. 1KD-FTV Engine

271EG108

Main Oil Hole CHECK VALVE

By-Pass Valve

Oil Filter

By-Pass Valve

Oil Cooler

Relief Valve

Oil Pump

Oil Strainer

Crankshaft Crankshaft Journal No.1 Journal No.2-5

Connecting Rod

Gear Oil Jet

Idle Gear Shaft

Vacuum Pump

TurboCharger 

Oil Jet

Piston

 No.1 Balance Shaft Journal

Drive Gear Thrust Washer

 No.2 Balance Shaft Journal

Orifice

Intake Exhaust Camshaft Camshaft Journal Journal

Drive Gear Thrust Washer

Valve Lifter

Valve Lifter

Cam Gear

Idle Gear Oil Pan 271EG109

EG-125

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES 2KD-FTV Engine

271EG110

Main Oil Hole By-Pass Valve

By-Pass Valve

Relief Valve

Crankshaft Journal No.1

Oil Filter

Oil

Gear Oil Jet

Idle Gear Shaft

TurboCharger 

Journal No.2-5

Oil Jet

Connecting Rod

Oil Cooler

Oil Pump

CHECK Crankshaft VALVE

Vacuum Pump

Piston

Valve Lifter

Orifice

Intake Camshaft Journal

Exhaust Camshaft Journal

Valve Lifter

Cam Gear

Idle Gear

Oil Pan 271EG111

Oil Capacity

Engine Type

 1KD-FTV

 2KD-FTV  2KD-FTV

Dry

liters (US qts, Imp. qts.)

7.4 (7.8, 6.5)

With oil filter

liters (US qts, Imp. qts.)

6.9 (7.3, 6.1)

Without oil filter

liters (US qts, Imp. qts.)

6.6 (7.0, 5.8)

High Version

EG-126

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

2. Piston Oil Jet   Piston

oil jets are provided at the bottom of the cylinder block to spray oil to the piston s cooling channel, thus further cooling and lubricating the piston.  These oil jets contain a check valve to prevent oil from being fed when the oil pressure is low. This  prevents the overall oil pressure in the engine from dropping. ’

Piston Oil Jet Cooling Channel

Check Valve Oil

Back Side View

271EG112

EG-127

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES 

COOLING SYSTEM

1. General  The cooling

system uses a pressurized forced circulation system with pressurized reservoir tank.  A pressurized reservoir tank has been adopted to prevent the engine coolant deteriorating upon contact with external air.  A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature distribution in the cooling system.  An aluminum radiator core is used for weight reduction.  A water-cooled type engine oil cooler is standard equipment.   A 3-stage temperature-controlled coupling fan, which uses the same bimetal that is used on the conventional model, controls the fan speed in three stages to improve cooling performance and reduce cooling fan noise.   The TOYOTA genuine Super Long Life Coolant (SLLC) has been adopted. As a result, the maintenance interval has been extended.

Reservoir Tank

Radiator

Oil Cooler

271EG113

Thermostat

Specifications

Transmission Type Type Engine Coolant

Thermostat

Capacity liters (US qts, Imp. qts) Opening Temperature C (F)

*1: Models with Heater *2: Models without Heater

MT

AT

TOYOTA Genuine Super Long Life Coolant (SLLC) or Equivalent 9.8 (10.4, 8.6)*1 11.1 (11.7, 9.8)*1 9.0 (9.5, 7.9)*2 10.3 (10.9, 9.1)*2 80-84 (176-183)



EG-128

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

EG-129

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES System Diagram

Radiator Water Outlet

Cylinder Head

Turbocharger

Cylinder Block

Oil Cooler Water Pump

Heater Core

Thermostat

Water Inlet Reservoir Tank

271EG114

Engine Coolant Specifications

Engine Coolant Type Color Maintenance Intervals   SLLC

TOYOTA Genuine Super Long Life Coolant (SLLC) or Equivalent

TOYOTA Genuine Long Life Coolant (LLC) or Equivalent

Pink

Red

First Time

160,000km (100,000miles)

Subsequent

Every 80,000 km (50,000 miles)

Every 40,000 km (24,000 miles) or 24 months whichever comes first

is pre-mixed (50% coolant and 50% deionized water), so no dilution is needed when adding or replacing SLLC in the vehicle.  If LLC is mixed with SLLC, the interval for LLC (every 40,000 km / 24,000 miles or 24 months) should  be used.   You can also apply the new maintenance interval (every 80,000 km /50,000 miles) to vehicles initially filled with LLC (red-colored), if you use SLLC (pink-colored) for the engine coolant change.

EG-130 

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

INTAKE AND EXHAUST SYSTEM

1. General  An

intake shutter valve (throttle valve) equipped with a torque motor (rotary solenoid type) is used.  Swirl control valves are provided in the intake manifold of the 1KD-FTV engine.  A stainless steel exhaust pipe is used for weight reduction and improved rust resistance.  An air-cooled intercooler is provided on the 1KD-FTV engine and 2KD-FTV High Version engine for Thailand.  An EGR system is provided on the models complying with the emission regulations (EURO III, EURO I, and Tier 1). This system is designed to reduce and control NOx formation through a slight reduction of peak temperature in the engine combustion chamber, which is accomplished by introducing a small amount of inert gas into the intake manifold. For details on EGR control, see page EG-169.  A variable nozzle vane type turbocharger is used on the 1KD-FTV engine.  An air-cooled type turbocharger is used on the 2KD-FTV engine.   An oxidation catalytic converter is provided on the models complying with the EURO III or Tier 1 emission regulation. Intake Shutter Assembly Intake Shutter Valve (Throttle Valve)

EGR Valve

Intercooler Exhaust Manifold

Air Cleaner

Muffler Turbocharger Intake Manifold

Oxidation Catalytic Converter

271EG115

EG-131

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

2. Intake Shutter Assembly The intake shutter valve (throttle valve) equipped with the torque motor (rotary solenoid type) is used to improve EGR performance and to reduce the vibration and noise when stopping the engine. The torque motor (rotary solenoid type) makes the intake shutter valve (throttle valve) respond quickly. Intake Shutter Valve Position Sensor

Torque Motor (Rotary Solenoid type)

Intake Shutter Valve (Throttle Valve)

271EG116

3. Intake Manifold  In

conjunction with the adoption of the direct injection system, an intake manifold provided with an air intake chamber is used in order to reduce the swirl variances between the cylinders.  On the 1KD-FTV engine, a vacuum-actuated swirl control valve is provided in one of the two intake  ports provided for each cylinder. A swirl control valve consists of a stainless steel shaft and an actuator, which are integrated in the valve. For details, see page EG-164. Air Intake Chamber

Actuator

271EG117

Swirl Control Valve 1KD-FTV Engine

EG-132

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

4. Intercooler  

An air-cooled intercooler is used in order to lower the intake air temperature, improve engine  performance, and to realize cleaner exhaust gas emissions. It is located directly on top of the engine.   The intercooler and the inlet tank are made of aluminum and the outlet tank is made of plastic for weight reduction.  A dual construction, high-frequency cavity resonator is used for the pipe between the turbocharger and the intercooler. Outlet Tank

Hight-Frequency Cavity Resonator

Intercooler

Inlet Tank Front

271EG118

5. EGR Valve   An

EGR valve is provided midstream in the intake air passage. By cooling the EGR valve in this manner, a greater volume of exhaust gas can be processed.  On the 1KD-FTV engine, a vacuum port for a VSV (for EGR Valve Close) to cut off EGR is used to improve valve closure response.  On the 2KD-FTV engine, an EGR valve position sensor has been provided in the EGR valve in order to directly measure the actual amount of the valve opening. This measurement is then input into the engine ECU in order to improve the precision of EGR control. EGR Valve Position Sensor Vacuum Port Vacuum Port

Intake Air

to Intake Manifold

EGR Gas 1KD-FTV Engine

271EG119

Intake Air

to Intake Manifold

EGR Gas 2KD-FTV Engine

271EG120

EG-133

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

6. Turbocharger General  A variable

nozzle vane type turbocharger is used for 1KD-FTV engine. A water jacket is provided in the bearing housing to improve the cooling performance of the turbocharger.  A lightweight and compact air cooled type turbocharger is used for 2KD-FTV engine. To control the turbo pressure, this turbocharger is provided with a wastegate valve and an actuator that operates mechanically in accordance with the turbo pressure. 1KD-FTV Engine 

DC Motor

DC Motor

Water Jacket

Turbine Wheel

 Nozzle Vane Position Sensor Compressor Wheel

271EG121

2KD-FTV Engine without Intercooler 

Compressor Wheel

Turbine Wheel

Wastegate Valve

271EG154

Service Tip Only for 2KD-FTV Engine Models The engine ECU determines altitude using the atmospheric pressure sensor. If the sensor indication value is approx. 85kPa or less (Altitude: Higher than approx. 1,500 m), the engine ECU lowers the  preset maximum engine speed*, in order to prevent the turbine wheel from racing when the vehicle is driven in high altitude areas (where the atmospheric pressure is low). Therefore, the preset maximum engine speed is lower than standard. However, this is not an engine malfunction. For details, see the Hilux Repair Manual.

*: Varies in accordance with altitude. As the altitude increases (the atmospheric pressure sensor

EG-134

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

Variable Nozzle Vane type Turbocharger  Variable

nozzle vane type turbocharger consists primarily of an impeller, turbine, nozzle vane, unison ring, DC motor and nozzle vane position sensor.   This turbocharger has realized great improvements in low-speed torque, maximum output, fuel consumption, and emission reduction. These improvements have been accomplished through variable control of the nozzle vane position, and an optimal velocity of the exhaust gas inflow to the turbine at all times in response to the engine condition.  The engine ECU outputs a signal to the turbo motor driver, which actuates the DC motor, to control the nozzle vane position. For details on the turbocharger control, see page EG-165. DC Motor

 Nozzle Vane Position Sensor

Turbine Wheel

Linkage 271EG146

 Nozzle Vane

Unison Ring

  The

exhaust gas from the exhaust manifold goes through the nozzle vane inside the turbo charger housing, and flows to the exhaust pipe through the turbine. The speed of the turbine (supercharging  pressure) differs depending on the flow velocity of the exhaust gas going through the turbine and the flow velocity of the exhaust gas is controlled by the opening. In such a time like idling, when the exhaust gas is less, the nozzle vane is almost fully closed, but as there is a slight clearance between the vanes, the exhaust gas flows through this clearance to the exhaust pipe. Therefore, there is no  bypass.

: Exhaust Gas : Intake Air

 Nozzle Vane

195EG72

EG-135

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

7. Exhaust Pipe  A

stainless steel exhaust pipe is used for weight reduction and rust resistance.   A ball joint is used to join the exhaust front pipe and exhaust manifold. As a result, a simple and reliable construction for reducing vibration has been realized.  The oxidation catalytic converter is used to clean the exhaust gas particulates, HC and CO. The table  below describes the location of the converter (where equipped), in accordance with the engine type and exhaust emission regulation compliance. EURO III or Tier 1

Emission Regulation Engine Type Location of Oxidation Catalytic Converter

1KD-FTV 2KD-FTV High Version (with Intercooler) Integrated with Front Exhaust Pipe

EURO I or  Non-Compliance

2KD-FTV 2KD-FTV High Version (without Intercooler) Below Exhaust Manifold

All   

Gasket Main Muffler

Oxidation Catalytic Converter 1KD-FTV Engine and 2KD-FTV Engine with Intercooler

271EG122

Gasket Main Muffler

Oxidation Catalytic Converter 2KD-FTV Engine without Intercooler

271EG151

EG-136

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

FUEL

SYSTEM

1. General  A common-rail system is

used in the fuel injection system.  HP3 type supply pump, which is compact and lightweight, is used.   An injector compensation value and a QR code are printed on the injector to realize high-precision control.  A new type of fuel filter, in which the fuel filter element alone can be replaced, has been adopted.  A fuel filter warning switch, which turns ON/OFF when the internal vacuum of the filter increases, is  provided in the fuel filter.  A fuel cooler made of aluminum has been adopted on the model equipped with an intercooler.  A fuel tank made of single-layer plastic has been adopted.

Fuel Filter Warning Switch

Fuel Cooler*

Common-Rail

Injector

Fuel Tank Supply Pump Fuel Filter

*: Only for Models with Intercooler

271EG123

EG-137

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

2. Common-Rail System General In this system, the high pressurized fuel that is supplied by the supply pump is stored in the common-rail, and the engine ECU sends signals to the injectors via the EDU (Electronic Driver Unit) in order to control the injection timing and injection volume. For details of this control, see page EG-156. System Diagram

Pressure Limiter

Fuel Pressure Sensor Common-Rail

Fuel Temp. Sensor 

SCV

Supply Pump

Fuel Filter Warning Light Pressure Switch

Fuel Filter 

Fuel Tank

Fuel Cooler*

 NE Signal EDU Engine ECU

G Signal 271EG124

*: Only for Models with Intercooler

EG-138

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

Supply Pump 1) General

This supply pump (HP3 type) has been made shorter than the HP2 type that is used on other models. This has been accomplished through the adoption of an opposing plunger configuration (and by reducing the number of plungers from 4 t o 2), resulting in a compact and lightweight supply pump.

B

B

A

A

271EG155

HP3

224EG21

HP2

Specifications

Model Type

 New Hilux

Other Model

HP3 (Outer Cam)

HP2 (Inner Cam)

A

Length

mm (in.)

190.2 (7.49)

252.0 (9.92)

B

Length

mm (in.)

129.0 (5.08)

182.1 (7.17)

1

2

Suction Control Valve Plunger Weight

φ8.5×2

g (lb.)

3,800 (8.38)

φ7.0×4

6,040 (13.32)

Service Tip

The engine ECU learns and memorizes the pump discharge volume variances associated with the individual differences in the supply pumps. Therefore, make sure to perform the operation described  below after replacing the supply pump. For details, see the Hilux Repair Manual.  Connect an intelligent tester II to the DLC3 connector and use the tester to reset the learned value. Alternatively, connect the SST (09843-18040) between the TC and CG terminals of the DLC3 connector, and leave the ignition switch ON for approximately 3 minutes to r eset the learned value.  After resetting, start the engine, allow it to idle* for approximately 1 minute, and turn the ignition switch OFF to enable the engine to memorize the learned value. *: The engine coolant temperature should be 60 C (140F) or more, and the fuel temperature should be 20C 68F or more.

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

EG-139

2) Construction  The

supply pump consists of an eccentric camshaft, ring cam, two plungers, four check valves, SCV (Suction Control Valve), fuel temperature sensor, and a feed pump.  The two plungers are placed opposite each other outside of the ring cam. to Fuel Tank (for Return)

Check Valve (for Suction)

Check Valve (for Discharge)

Plunger 

to Common-rail from Fuel Tank (for Suction)

Eccentric Camshaft

Feed Pump Fuel Temp. Sensor

Ring Cam

Plunger 

SCV

Check Valve (for Suction) 271EG156

Check Valve (for Suction)

Check Valve (for Discharge)

Plunger  Eccentric Camshaft

Eccentric Cam Portion Feed Pum Ring Cam

Eccentric Cam Portion Plunger  Ring Cam Check Valve (for Suction)

271EG157

271EG158

EG-140

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

3) Operation   Due

to the rotation of the eccentric cam, the ring cam pushes plunger A   upward as illustrated  below. The force of the spring pulls plunger B  (which is located opposite plunger A ) upward. As a result, plunger B draws fuel in, and plunger A  pumps fuel at the same time.  The SCV controls the volume of fuel that is drawn into the plungers in accordance with the signals from the engine ECU. “

“

”

“

Check Valve (for Suction)

Eccentric Cam

”

“

”

”

Check Valve (for Discharge)

A

SCV

B

Ring Cam

Engine ECU

Engine ECU

Engine ECU

Engine ECU

245EG08

EG-141

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

Common-Rail  The

function of the common-rail is to store the fuel that has been pressurized by the supply pump. The common-rail is provided with a fuel pressure sensor, which detects the fuel pressure in the common-rail, and a pressure limiter that mechanically relieves the pressure in case the internal  pressure of the common-rail rises abnormally.  Internally, the common-rail contains a main hole and five branch holes that intersect the main hole. Each branch hole functions as an orifice that dampens the fluctuation of the fuel pressure. to Injectors

Pressure Limiter Fuel Pressure Sensor

from Supply Pump Branch Hole Main Hole

Common-Rail Cross Section

271EG125

Service Tip  

Fuel pressure sensor has its sealing portion plastic-deformed in order to keep sealing  performance, so do not reuse it after disassembling.   If parts that affect the alignment have been changed, make sure to replace the pipe with a new one as well. The parts that require the replacement of a pipe are listed below. Injection Pipe: Injector, Common-rail, and Cylinder Head Fuel Inlet Pipe: Supply Pump, Common-rail, Cylinder Block, Water Pump, and Cylinder Head For details, refer to the Hilux Repair Manual.

EG-142

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

Injector 1) General  An

injector consists of a nozzle needle, piston, and solenoid valve.  An injector compensation value and QR (Quick Response) code containing encoded characteristics of the injector are printed on each injector.   The injector compensation value and QR code contain various pieces of information regarding the injector, such as model code, and injection volume correction.

Solenoid Valve

Piston

 Nozzle Needle

271EG152

Service Tip   If

the engine ECU is replace, use the intelligent tester II and input the injector compensation values of all 4 injectors. If the injector is replaced, input the injector compensation value of the replaced injector. Then, the proper compensation will be made so that the injection volume  precision prior to the replacement will remain unchanged. For details, see the Hilux Repair Manual.  The QR code, which requires a special scan tool, is not used at Toyota dealers.

Injector Compensation Value

QR Code 271EG153

- REFERENCE  -

What is QR (Quick Response) Code?   QR code, a matrix symbology consisting of an array of nominally square cells, allows omni-directional, high-speed reading of large amounts of data.   QR code encodes many types of date such as numeric, alphanumeric, kanji, kana and binary code. A maximum of 7,089 characters (numeric) can be encoded.  QR code (2D code) contains information in the vertical and horizontal direction, whereas a bar code contains date in one direction only. QR code (2D code) holds a considerably greater volume of information than a bar code.

EG-143

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES 2) Operation

(a) When electrical current is applied to the solenoid coil, it pulls the solenoid valve up. (b) The orifice of the control chamber opens, allowing the fuel to flow out. (c) The fuel pressure in the control chamber drops. (d) Simultaneously, fuel flows from the orifice to the bottom of the piston and raises the piston up (to enhance response). (e) As a result, the piston raises the nozzle needle to inject fuel.

Solenoid Coil

(a)

Solenoid Valve

Fuel Piston

(b)

Fuel (c)

Control Chamber

(d)  Nozzle  Needle (e) 271EG127

EG-144

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

3. Fuel Filter General  The

conventional fuel filter consists of a fuel filter element integrated with the fuel filter housing. By contrast, the new fuel filter consists of a separate fuel filter housing and a fuel filter element.  A paper filter element that offers high filtering efficiency and captures the minutest particles has been adopted. Fuel Filter Warning Switch

Priming Pump

Priming Pump

Filter Element Fuel Filter Assembly  Filter Element Filter Housing

Fuel Sedimenter Level Warning

New

Fuel Sedimenter Level Warning

Conventional

271EG128

Fuel Filter Warning Switch  A

fuel filter warning switch, which turns ON/OFF when the internal vacuum of the filter increases, is  provided in the fuel filter. This switch, which turns OFF when the internal vacuum of the fuel filter increases to a predetermined level, is connected by wire to the meter ECU.  When the meter ECU detects that the internal vacuum of the fuel filter has increased (by way of the fuel filter warning switch OFF signal), it determines that the fuel filter has become clogged. Then, it illuminates the fuel filter warning light on the combination meter to urge the driver to replace the fuel filter. For details on fuel filter warning light control, see page BE-XX. Combination Meter

Combination Meter Fuel Filter Warning Light

Meter ECU

Fuel Filter Warning Switch

Meter ECU

Diaphragm from Fuel Tank

 Negative Pressure Vacuum

Filter Element

to Supply Pump Fuel Filter

Fuel Filter 271EG129

Normal Fuel Filter

Fuel Filter Clogged Up

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

EG-145

EG-146

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES

4. Fuel Cooler The fuel cooler, which is provided in the fuel return path, cools the return fuel that has reached a high temperature as a result of the pumping of the supply pump. This prevents the reduction in fuel viscosity that is caused by the rise in fuel temperature, and improves the reliability of the fuel system.

A

to Fuel Tank

A

from Common-Rail

A-A Cross Section

271EG130

EG-147

ENGINE  –  1KD-FTV AND 2KD-FTV ENGINES CHARGING SYSTEM   As

on the 2TR-FE engine model, a compact and lightweight segment conductor type alternator (SE08 type) that generates a high amperage output in a highly efficient manner has been adopted as standard equipment on models except the Central and South American models. For details on this alternator, see page EG-28.   The Central and South American models have adopted the conventional (KCB1 type) alternator made by Bosch.   A one-way clutch function has been provided in the pulley of 2 type alternators to absorb the fluctuations in the engine speed, thus significantly reducing the damage sustained by the drive belt.

One-way Clutch

Alternator Pulley 271EG165

Service Tip

SST (09820-63020) has been established due to the adoption of a pulley with the one-way clutch function. For details, refer to the Hilux Repair Manual.

STARTING  As

SYSTEM

on the Central and South American 2TR-FE engine models, a planetary reduction type starter with an interpolar magnet (DW2.2 type) has been adopted on the Central and South American models (except KUN26L-PRPSYG). For details on the interpolar magnet, see page EG-32.  The models except those indicated above use a conventional reduction type starter (RA2.0, R2.2, or R2.7 type).