Engine 1KD, 2KD
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KD Series Engine
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Chassis
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Body Electrical
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KD Series Engine
Chassis
Engine Overall Engine Proper Valve Mechanism Lubrication System Intake and Exhaust System Common-rail System Fuel System Charging System Serpentine Belt Drive System
Body
Body Electrical
Model Outline
KD Series Engine
Chassis
Engine Overall Engine Proper Valve Mechanism Lubrication System Intake and Exhaust System Common-rail System Fuel System Charging System Serpentine Belt Drive System
Body
Body Electrical
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Engine Overall 1KD-FTV / 2KD-FTV – TOYOTA D-4D, 3.0 / 2.5 liter, in-line 4-cylinder, 16 valve DOHC with turbocharged diesel engine
1KD-FTV
2KD-FTV
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Engine Overall 1KD-FTV / 2KD-FTV Specifications 1KD-FTV (HILUX)
2KD-FTV (HILUX, INNOVA)
No. of Cylinders & Arrangement
4-Cylinder, In-line
Valve Mechanism
16-Valve DOHC, Belt & Gear Drive
Common-Rail Type
With
Without / With * 2
cm3 (cu. in.)
2,982 (182.0)
2,492 (152.2)
mm (in.)
96.0 x 103.0 (3.78 x 4.06)
92.0 x 93.8 (3.62 x 3.69)
18.4
18.5
120 @ 3,400
75 @ 3,600 88 @ 3,600 *2
343 @1,400 ~ 3,200
200 @ 1,400 ~ 3,200 260 @ 1,600 ~ 2,400 *1 320 @ 2,000 *2
Item
Fuel System Intercooler Displacement Bore x Stroke Compression Ratio Max. Output kW @ rpm Max. Torque N·m @ rpm
*1: 2KD-FTV High Version
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KD Series Engine
Chassis
Body
Body Electrical
Engine Overall Features – Engine compartment Rotary Solenoid Type Diesel Throttle
VN Type Turbocharger (1KD only)
Photo: 1KD-FTV SLLC
Fuel Filter •Fuel filter warning (clogging detection)
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KD Series Engine
Chassis
Body
Body Electrical
Engine Overall Features – Under floor
Front
Fuel Cooler (with intercooler model only)
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KD Series Engine
Chassis
Body
Body Electrical
Engine Proper Piston – In conjunction with the adoption of direct injection, combustion chamber is provided on piston
Combustion Chamber SIRM Ring Carrier
Ni-resist Cast Iron Ring Carrier
Cooling Channel
1KD-FTV
2KD-FTV
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Valve Mechanism Timing Belt – Maintenance interval: replace at every 150,000 km Camshaft Timing Pulley No. 2
Oil Pump Drive Gear Crankshaft Timing Gear Supply Pump Drive Gear
Timing Belt
Automatic Belt Tensioner Camshaft Timing Pulley No. 1
Vacuum Pump Drive Gear
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KD Series Engine
Chassis
Body
Body Electrical
Lubrication System Lubrication System – Overall • Lubrication is fully pressurized and all oil passes through an oil cooler and oil filter
Oil Filter
Oil Cooler
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Intake Shutter Valve – Rotary solenoid type intake shutter valve is used to improve EGR performance Engine Condition
Valve Position
Purpose
Starting
Full Open
Reduced Diesel Smoke
Running
Small Full Open
Stop
Full Close
Controls EGR amount Reduced noise and vibration Air flow
Intake Shutter Valve
Rotary Solenoid type Motor
Intake Shutter Valve Position Sensor
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Intake Shutter Valve – Construction
Intake Shutter Valve Position Sensor
Rotary Solenoid Type Motor
Steel Layer Magnet Hall IC Magnet Magnet
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Intake Manifold – Two intake port with different shape from intake manifold to cylinder head • For swirl optimizing in cylinder
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Swirl Control Valve (1KD only) – Swirl control valve is provided to realize clean emission
Intake Manifold
Actuator
Swirl Control Valve
VSV for SCV
1KD-FTV only
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Swirl Control Valve (1KD only) – Operation
Intake Air At low engine speed, SCV is closed to strengthen the swirl
Actuator
Vacuum Pump Engine Speed
VSV ON / OFF
Engine ECU
Accelerator Pedal Opening
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Chassis
KD Series Engine
Body
Body Electrical
Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Nozzle Vane is driven by DC motor DC Motor
Nozzle Vane Position Sensor Turbine Wheel Motor Rod
Link
FullClose
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Chassis
KD Series Engine
Body
Body Electrical
Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Construction Exhaust Gas
DC Motor Intake Air
Nozzle Vane Position Sensor Turbine Wheel
Reduction Gears Motor Rod
Link Nozzle Vane
FullClose
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Construction Motor Rod
Gas Flow
Drive Arm Turbine Wheel
Link Unison Ring
Nozzle Vane
Driven Arm
Full-Close Stopper
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Feedback Control Injector (EDU) Crankshaft Position Sensor Turbo Pressure Sensor Atmospheric Temp. Sensor Water Temp. Sensor
Target Angle
Engine ECU
Control Status
Turbo Motor Driver Control
Atmospheric Pressure Sensor
Nozzle Vane Position
DC Motor Nozzle Vane Position Sensor
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Zero point calibration Link is bumped to full-close stopper
IG ON
OFF
Zero point calibration
IG OFF
ON
Motor Rod Open
0 Link Close
After the engine start
Nozzle vane is controlled based on the zero point
0
Full-Close Stopper
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Operation movie
Click! Movie
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Turbocharger (2KD only) – Light weight, compact and high performance turbocharger
Waste Gate Valve
Actuator for Waste Gate Valve
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Intercooler – Intake air is cooled in intercooler to increase the air density Thermal Expansion Oxygen
Turbocharger
Increase oxygen density
Contraction
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KD Series Engine
Chassis
Body
Body Electrical
Intake and Exhaust System Intercooler – Intake air is cooled in intercooler to increase the air density
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Chassis
KD Series Engine
Body
Body Electrical
Fuel System General NE Signal
Engine ECU
G Signal
EDU Other Injectors
Various Signals Fuel Pressure Sensor
Pressure Limiter Common-rail Injector Pressure Switch
Fuel Cooler SCV Supply Pump
Fuel Filter Fuel System Warning Light
Fuel Tank
Model Outline
Chassis
KD Series Engine
Body
Body Electrical
Fuel System Features NE Signal
Engine ECU
G Signal
EDU
Injector compensation code
Other Injectors
Various Signals
Max. 160MPa
HP3 Type Fuel Pressure Supply Sensor Pump
Pressure Limiter Common-rail Injector Pressure Switch
Fuel Cooler
Warning Supplylight Pump for fuel filter clogging and fuel sedimenter
SCV
Fuel Filter Fuel System Warning Light Detects
filter clogging
Element replacement type
Fuel Tank
Fuel cooler cools return fuel
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System General – This system realize high injection pressure in all speed range of the engine NE Signal G Signal
EDU (Operates injector at high-speed)
Engine ECU
Various Signals Fuel Pressure Sensor
Pressure Limiter
Common-rail (Stores high-pressure fuel)
Injector (Injects high-pressure fuel)
SCV Supply Pump (Generates high-pressure fuel)
Fuel Tank
: High-pressure (Max. 160 MPa)
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System System Outline Common-rail Diesel Constant high pressure Pressure Common-rail Sensor
Conventional Diesel Instantaneously high pressure
System
Governor
SCV
Timer ECU
Supply Pump
Injector
Pump
Injection Nozzle
Injection Volume Control
ECU (Injector)
Pump (Governor)
Injection Timing Control
ECU (Injector)
Pump (Timer)
Injection Pressure Control
Supply Pump (SCV)
According to rotational speed and injection quantity
Pressurization
Supply Pump
Pump
Distribution
Common-rail
Pump
Injection Pressure
Max. 160 MPa
Approx. 15 MPa
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Location Engine Front
Injection Pipe
Injector
Fuel Inlet Pipe
Common-rail Supply Pump •SCV (Suction Control Valve) •Fuel Temp. Sensor
•Fuel Pressure Sensor •Pressure Limiter
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Supply Pump – Supplies the high pressure fuel to the common-rail – Driven by crankshaft
To Common-rail (Outlet)
To Fuel Tank (Return)
SCV (Suction Control Valve)
From Fuel Filter (Inlet)
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Supply Pump – Construction
Check Valve
Eccentric and Ring Cam
Plunger
Delivery Valve
Feed Pump
Fuel Temp. Sensor SCV (Suction Control Valve)
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Supply Pump – Construction To fuel tank (return)
Ring Cam
Plunger Eccentric Cam
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Chassis
KD Series Engine
Common-rail System Supply Pump – Fuel flow
To common-rail
From fuel tank
Body
Body Electrical
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KD Series Engine
Chassis
Body
Common-rail System Supply Pump – Fuel flow (reference)
Click! Movie
Body Electrical
Model Outline
Chassis
KD Series Engine
Body
Body Electrical
Common-rail System Supply Pump – Suction and pumping operation
Plunger A: Suction Plunger B: Pumping
Plunger A: Pumping Plunger B: Suction
Check Valve Plunger A SCV
Plunger B
: From Feed Pump
: To Common-rail
Model Outline
KD Series Engine
Chassis
Body
Common-rail System Supply Pump – Suction and pumping operation
Click! Movie
Body Electrical
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Supply Pump – Fuel control operation (SCV opening small)
Fuel Pumping Mass
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Supply Pump – Fuel control operation (SCV opening large)
Fuel Pumping Mass
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KD Series Engine
Chassis
Body
Common-rail System Supply Pump – Fuel control operation (SCV opening small)
Click! Movie
Body Electrical
Model Outline
KD Series Engine
Chassis
Body
Common-rail System Supply Pump – Fuel control operation (SCV opening large)
Click! Movie
Body Electrical
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Supply Pump – The SCV opening regulates the pumping volume to control fuel pressure [Fuel Pressure Control] Fuel Pressure Sensor
SCV Controls SCV opening
Common-rail pressure (Feedback)
Calculation of target injection pressure
Engine ECU
Crankshaft Position Sensor
Accelerator Pedal Position Sensor
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Common-rail – Stores high-pressure fuel (Max. 160 MPa) produced by supply pump Pressure Limiter
Fuel Pressure Sensor
Common-rail
From Supply Pump
To Injector
To Fuel Tank
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Common-rail – Fuel pressure sensor • Detects the internal fuel pressure of common-rail
Output characteristic
Sensor Tip
) V ( e4.04 g a t l o2.44 V t u 1.0 p t u O
Common-rail Pressure
0 90 190 Common-rail Pressure (MPa)
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Chassis
KD Series Engine
Body
Body Electrical
Common-rail System Injector – High pressure injection for higher atomization
Return to Fuel Tank
From Common-rail
Injector Compensation Code
0.14 mm
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Injector – Construction Solenoid Coil
Return to Fuel Tank
From Common-rail
Piston
Nozzle Spring
Nozzle Needle
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KD Series Engine
Chassis
Body
Common-rail System Injector – Controlled by engine ECU signal Solenoid Solenoid TWV Small Orifice From Common-rail
Click! Movie
Return
Large Orifice
Body Electrical
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Injector – Pilot injection reduces NOx and engine noise Main
Injection Volume
Pilot
NOx and engine noise
Heat Release Value
TDC
Pilot Injection Control
TDC
Conventional Injection Control
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Injector – Pilot injection reduces NOx and engine noise
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System EDU (Electronic Driver Unit) – Drive the injectors at high speed
EDU Battery DC / DC Converter Command Pulse
IJT #1-4
IJF
Engine ECU
Confirmation Pulse
Control Circuit
High Voltage
High-speed operation
Injector
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KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Diagnosis – DTCs for common-rail system Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Trouble Area
P0087 (49)
Fuel Rail/System Pressure - Too Low
•Open or short in fuel pressure sensor circuit •Fuel pressure sensor •Engine ECU
P0088 (78)
Fuel Rail/System Pressure - Too High
•Short in supply pump (SCV) circuit •Supply pump (SCV) •Engine ECU
P0093 (78)
Fuel System Leak Detected - Large Leak
•High pressure fuel line •Open or short in EDU circuit •Open or short in injector circuit •Supply pump •Common-rail •Injectors •EDU •Engine ECU
P0190 (49)
Fuel Rail Pressure Sensor Circuit Malfunction
P0192 (49)
Fuel Rail Pressure Sensor Circuit Low Input
P0193 (49)
Fuel Rail Pressure Sensor Circuit High Input
• Open or short in fuel pressure sensor circuit •Fuel pressure sensor •Engine ECU
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Diagnosis – DTCs for common-rail system Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Detection Condition
P0087 (49)
Fuel Rail/System Pressure - Too Low
Fuel pressure sensor output voltage stays at fixed value
P0088 (78)
Fuel Rail/System Pressure - Too High
Fuel pressure exceeds predetermined value
P0093 (78)
Fuel System Leak Detected - Large Leak
Difference of common-rail pressure before and after fuel injection varies greatly from difference of value that engine ECU calculates before and after injection
P0190 (49)
Fuel Rail Pressure Sensor Circuit Malfunction
Fuel pressure sensor output voltage is 0.55V or less, or 4.9V or more for 0.5 sec.
P0192 (49)
Fuel Rail Pressure Sensor Circuit Low Input
Fuel pressure sensor output voltage is 0.55V or less for 0.5 sec.
P0193 (49)
Fuel Rail Pressure Sensor Circuit High Input
Fuel pressure sensor output voltage is 4.9V or more for 0.5 sec.
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Diagnosis – DTCs for common-rail system Trouble Area
DTC No.
Detection Item
P0087 (49)
Fuel Rail/System Pressure - Too Low
P0088 (78)
Fuel Rail/System Pressure - Too High
P0093 (78)
Fuel System Leak Detected - Large Leak
P0190 (49)
Fuel Rail Pressure Sensor Circuit Malfunction
P0192 (49)
Fuel Rail Pressure Sensor Circuit Low Input
P0193 (49)
Fuel Rail Pressure Sensor Circuit High Input
Detection Condition
Fail-safe
Fail-safe
Limits engine power
Limits engine power for 1 min., and then stops the engine
Limits engine power
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Diagnosis – DTCs for common-rail system Trouble Area
DTC No.
P0200 (97)
P0627 (78)
Detection Item
Injector Circuit / Open
Fuel Pump Control Circuit / Open
Detection Condition
Fail-safe
Trouble Area •Open or short in EDU circuit •EDU •Injector •Engine ECU •Open or short in (SCV) circuit •SCV •Engine ECU
P1229 (78)
Fuel Pump System
•Short in supply pump (SCV) circuit •Supply pump (SCV) •Engine ECU
P1601 (89)
Injector Correction Circuit Malfunction (EEPROM)
•Injector compensation code •Engine ECU
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Diagnosis – DTCs for common-rail system Trouble Area
DTC No.
P0200 (97)
P0627 (78)
Detection Item
Injector Circuit / Open
Fuel Pump Control Circuit / Open
Detection Condition
Fail-safe
Detection Condition Open or short in EDU or injector circuit. After engine is started, there is no injection confirmation (IJF) signal from EDU, despite engine ECU sending injection command (IJT) signal to EDU Open or short in suction control valve circuit for more than 0.5 sec.
P1229 (78)
Fuel Pump System
Fuel over-feed: Fuel pressure continues exceeding target fuel pressure despite engine ECU closing SCV
P1601 (89)
Injector Correction Circuit Malfunction (EEPROM)
Injector compensation code is not registered
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Diagnosis – DTCs for common-rail system Trouble Area
DTC No.
P0200 (97)
P0627 (78)
Detection Item
Detection Condition
Fail-safe
Injector Circuit / Open
Fuel Pump Control Circuit / Open
P1229 (78)
Fuel Pump System
P1601 (89)
Injector Correction Circuit Malfunction (EEPROM)
Limits engine power
-
Fail-safe
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Common-rail System Service Point for Common-rail System – Supply pump initialization and calibration – Common-rail replacement – Reprogramming of injector compensation code – Replace a new parts – Replace a new pipe – Check fuel leak (Leakage Pipe No.1 / Fuel System) – Power Balance Check
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Fuel System Fuel Filter – Replace fuel filter element only Priming Pump
From Fuel Tank
Fuel Filter Warning Switch
To Supply Pump
Fastener Nut Filter Housing (Plastic)
Filter Element
Drain Cock
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Fuel System Fuel Filter – Construction Priming Pump
From Fuel Tank
Fuel Filter Warning Switch
To Supply Pump
Fastener Nut Filter Element
Filter Housing (Plastic)
Fuel Sedimenter Level Warning Switch
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Fuel System Fuel Warning System – Fuel filter clogging is detected by fuel filter warning switch Fuel Filter Warning Switch
Fuel System Warning Light
Clogging Combination Meter Fuel Filter - Fuel Filter Maintenance Interval -
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Fuel System Fuel Warning System – System Diagram Combination Meter Vehicle Speed Sensor Fuel Filter Warning Switch
Meter ECU Fuel System Warning Light
To Supply Pump
Filter Element
Fuel Filter
Fuel Sedimenter Level Warning Switch
Model Outline
Chassis
KD Series Engine
Body
Body Electrical
Fuel System Fuel Warning System – Fuel filter warning switch turns OFF when the filter outlet pressure decreases Fuel Filter Warning Switch
ON Meter
Fuel Filter Warning Switch
OFF Meter
ECU
ECU
Diaphragm To Supply Pump
Filter Element
Normal Fuel Filter (Switch: ON)
To Supply Pump
Negative Pressure
Fuel Filter Clogged Up (Switch: OFF)
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Fuel System Fuel Warning System – Warning light condition for fuel filter / fuel sedimenter
Warning
Warning Method
Sedimenter Warning
Priority
1 Blink
Fuel Filter Warning
2 ON
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Fuel System Fuel Warning System – Detection conditions After the driving for 30 min. or more
Fuel Filter Warning Switch Condition OFF for 10 min. or more
or
OFF is detected for 2 times during 1 trip
The warning light keeps ON until the reset operation is done
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Charging System Alternator Pulley • In order to absorb a engine fluctuation, one-way clutch was adopted in the pulley
Spring
Roller
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Charging System Alternator Pulley – Engine fluctuation absorbing mechanism One-way Clutch Locked
Crankshaft Pulley Speed
One-way Clutch Free
Alternator Pulley Speed
) m p r ( d e e p S y e l l u P
Engine Fluctuation
Time
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Serpentine Belt Drive System Serpentine Belt Drive – Single V-ribbed belt
Air Conditioner Compressor Pulley
Idler Pulley
Idler Pulley
Water Pump Pulley
Alternator Pulley with Shock Absorbing Function
Idler Pulley for Automatic Tensioner
Crankshaft Pulley
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Reference Intake Shutter Valve – Intake shutter valve position sensor
Magnet Hall IC VC
Engine ECU
VLU
E2
5
) V ( e 3.51 g a t l o V t u p t 1 u 0.71 O
0
20 0 (Full Close)
Intake Shutter Valve Position Sensor
70 (Full Open)
Intake Shutter Valve Opening Angle (°)
100
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Reference Variable Nozzle Vane Type Turbocharger (1KD only) – Nozzle Vane Position Sensor • Non-contact type position sensor Hall ICs Output characteristic of main, sub sensor
Magnets
Cross-section 0 -55
55
) V ( 4.5 e g a t l o 2.5 V t u p t u 0.5 O
-55
0 55 Sensor shaft rotation angle ( )
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Reference Fuel Cooler – A fuel cooler cools the return fuel – It is used on the model equipped with an intercooler Front
Fuel Cooler (Aluminum)
From Supply Pump / Injector
To Fuel Tank
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Reference Fuel Cooler – Construction
Fin
Cross Section
To Fuel Tank
From
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Reference Accelerator Pedal – Non-contact type accelerator pedal position sensor is used Accelerator Pedal Position Sensor
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