Contents

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Engine Overall Engine Proper Valve Mechanism Lubrication System Intake and Exhaust System Common-rail System Fuel System Charging System Serpentine Belt Drive System

Engine Overall

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Engine Overall
Item No. of Cylinders & Arrangement Valve Mechanism Fuel System Intercooler

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

1KD-FTV / 2KD-FTV Specifications

1KD-FTV (HILUX) 4-Cylinder, In-line 16-Valve DOHC, Belt & Gear Drive Common-Rail Type With 2KD-FTV (HILUX, INNOVA) Without / With *2

Displacement
Bore x Stroke

cm3 (cu. in.)

mm (in.)

2,982 (182.0)
96.0 x 103.0 (3.78 x 4.06) 18.4 120 @ 3,400 343 @1,400 ~ 3,200

2,492 (152.2)
92.0 x 93.8 (3.62 x 3.69) 18.5 75 @ 3,600 88 @ 3,600 *2 200 @ 1,400 ~ 3,200 260 @ 1,600 ~ 2,400 *1 320 @ 2,000 *2

Compression Ratio Max. Output Max. Torque

kW @ rpm
Nm @ rpm

*1: 2KD-FTV High Version *2: 2KD-FTV High Version (HILUX for Thai only)

Engine Overall

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Features Engine compartment

VN Type Turbocharger (1KD only) Rotary Solenoid Type Diesel Throttle

Photo: 1KD-FTV SLLC

Fuel filter warning (clogging detection) Element replacing type

Fuel Filter

Engine Overall

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Features Under floor

Fuel Cooler (with intercooler model only)

Front

Engine Proper

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Piston In conjunction with the adoption of direct injection, combustion chamber is provided on piston

SIRM Ring Carrier

Combustion Chamber Ni-resist Cast Iron Ring Carrier

Cooling Channel

1KD-FTV

2KD-FTV

Valve Mechanism

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Timing Belt Maintenance interval: replace at every 150,000 km

Camshaft Timing Pulley No. 2 Timing Belt Oil Pump Drive Gear Crankshaft Timing Gear Supply Pump Drive Gear

Automatic Belt Tensioner Camshaft Timing Pulley No. 1

Vacuum Pump Drive Gear Idle Gear

Lubrication System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Lubrication System Overall Lubrication is fully pressurized and all oil passes through an oil cooler and oil filter

Oil Filter

Oil Cooler

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Intake Shutter Valve Rotary solenoid type intake shutter valve is used to improve EGR performance
Engine Condition Starting Running Stop Valve Position Full Open Small Full Open Full Close

Purpose
Reduced Diesel Smoke Controls EGR amount Reduced noise and vibration Air flow Intake Shutter Valve Position Sensor

Intake Shutter Valve

Rotary Solenoid type Motor

Intake and Exhaust System

Intake Shutter Valve Construction

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Intake Shutter Valve Position Sensor

Rotary Solenoid Type Motor

Steel Layer Magnet

Hall IC
Magnet Magnet

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Intake Manifold Two intake port with different shape from intake manifold to cylinder head For swirl optimizing in cylinder

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Swirl Control Valve (1KD only) Operation

Intake Air
At low engine speed, SCV is closed to strengthen the swirl

Actuator

Vacuum Pump VSV Engine ECU

Engine Speed

ON / OFF

Accelerator Pedal Opening

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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 Stopper

Intake and Exhaust System

Gas

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Variable Nozzle Vane Type Turbocharger (1KD only) Construction Exhaust

DC Motor
Intake Air

Nozzle Vane Position Sensor Turbine Wheel Reduction Gears Motor Rod

Link Nozzle Vane

FullClose Stopper

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Variable Nozzle Vane Type Turbocharger (1KD only) Construction

Gas Flow Motor Rod Drive Arm Turbine Wheel

Link Nozzle Vane

Unison Ring Driven Arm Full-Close Stopper

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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 Nozzle Vane Position

Atmospheric Pressure Sensor

DC Motor Nozzle Vane Position Sensor

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Variable Nozzle Vane Type Turbocharger (1KD only) Zero point calibration
IG
Link is bumped to full-close stopper

ON OFF

IG
OFF ON

Zero point calibration

Motor Rod Open Link

Close

After the engine start

Nozzle vane is controlled based on the zero point

Full-Close Stopper

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Variable Nozzle Vane Type Turbocharger (1KD only) Operation movie

Click! Movie

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Turbocharger (2KD only) Light weight, compact and high performance turbocharger

Waste Gate Valve

Actuator for Waste Gate Valve

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Intercooler Intake air is cooled in intercooler to increase the air density

Thermal Expansion
Oxygen

Increase oxygen density

Contraction

Turbocharger

Intake and Exhaust System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Intercooler Intake air is cooled in intercooler to increase the air density

Fuel System
General
NE Signal G Signal Various Signals

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Engine ECU

EDU
Other Injectors Pressure Limiter Common-rail Injector Pressure Switch

Fuel Pressure Sensor

Fuel Cooler SCV Supply Pump Fuel Filter Fuel Tank

Fuel System Warning Light

Fuel System
Features
NE Signal G Signal Various Signals

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Engine ECU

EDU
Other Injectors

Injector compensation code

Pressure Limiter

Max. 160MPa

HP3 Type Fuel Pressure Supply Sensor Pump

Common-rail Injector Pressure Switch

Fuel Cooler SCV Fuel Filter

Warning light Supply Pump for fuel filter clogging and fuel sedimenter

Fuel System Warning Light Detects

Fuel Tank

filter clogging

Element replacement type

Fuel cooler cools return fuel

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

General This system realize high injection pressure in all speed range of the engine
NE Signal
G Signal Various Signals
Fuel Pressure Sensor

Engine ECU

EDU (Operates injector at high-speed)

Common-rail
(Stores high-pressure fuel)

Pressure Limiter

Injector (Injects high-pressure fuel)

SCV Supply Pump (Generates high-pressure fuel)

Fuel Tank

: High-pressure (Max. 160 MPa)

Common-rail System
System Outline

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Common-rail Diesel
Constant high pressure Pressure Common-rail Sensor

Conventional Diesel
Instantaneously high pressure

System

SCV ECU Supply Pump Injector

Timer

Governor

Pump

Injection Nozzle

Injection Volume Control Injection Timing Control Injection Pressure Control Pressurization Distribution

ECU (Injector) ECU (Injector) Supply Pump (SCV) Supply Pump Common-rail

Pump (Governor) Pump (Timer) According to rotational speed and injection quantity Pump Pump

Injection Pressure

Max. 160 MPa

Approx. 15 MPa

Common-rail System
Location

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Engine Front

Injection Pipe

Injector

Fuel Inlet Pipe

SCV (Suction Control Valve) Fuel Temp. Sensor

Supply Pump

Fuel Pressure Sensor Pressure Limiter

Common-rail

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Supplies the high pressure fuel to the common-rail Driven by crankshaft

To Common-rail (Outlet)

From Fuel Filter (Inlet)

To Fuel Tank (Return)

SCV (Suction Control Valve)

Common-rail System
Supply Pump Construction

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Check Valve

Eccentric and Ring Cam

Delivery Valve

Plunger

Feed Pump

Fuel Temp. Sensor SCV (Suction Control Valve)

Common-rail System
Supply Pump Construction

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

To fuel tank (return)

Ring Cam

Plunger

Eccentric Cam

Common-rail System
Supply Pump Fuel flow

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

To common-rail

From fuel tank

Common-rail System
Supply Pump Fuel flow (reference)

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Click! Movie

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Suction and pumping operation

Plunger A: Suction Plunger B: Pumping Check Valve Plunger A SCV

Plunger A: Pumping Plunger B: Suction

Plunger B

: From Feed Pump

: To Common-rail

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Suction and pumping operation

Click! Movie

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Fuel control operation (SCV opening small)

Fuel Pumping Mass

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Fuel control operation (SCV opening large)

Fuel Pumping Mass

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Fuel control operation (SCV opening small)

Click! Movie

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Supply Pump Fuel control operation (SCV opening large)

Click! Movie

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Crankshaft Position Sensor

Engine ECU

Accelerator Pedal Position Sensor

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Common-rail Fuel pressure sensor Detects the internal fuel pressure of common-rail

Sensor Tip

Output characteristic Output Voltage (V)

4.04 2.44 1.0

0 90 190 Common-rail Pressure (MPa)

Common-rail Pressure

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Injector High pressure injection for higher atomization

Injector Compensation Code

Return to Fuel Tank

From Common-rail

0.14 mm

Common-rail System
Injector Construction

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Solenoid Coil From Common-rail

Return to Fuel Tank

Piston

Nozzle Spring

Nozzle Needle

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Injector Controlled by engine ECU signal

Solenoid Solenoid TWV Small Orifice
From Common-rail Return

Large Orifice

Click! Movie

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Injector Pilot injection reduces NOx and engine noise

Main

Injection Volume

Pilot

NOx and engine noise

Heat Release Value

TDC

TDC

Pilot Injection Control

Conventional Injection Control

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Injector Pilot injection reduces NOx and engine noise

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

EDU (Electronic Driver Unit) Drive the injectors at high speed

EDU
Battery DC / DC Converter Command Pulse High Voltage

IJT #1-4

Control Circuit

IJF

High-speed operation

Engine ECU

Confirmation Pulse

Injector

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis DTCs for common-rail system

Trouble Area Detection Condition Fail-safe

DTC No. P0087 (49) P0088 (78) P0093 (78) P0190 (49) P0192 (49) P0193 (49)

Detection Item Fuel Rail/System Pressure - Too Low Fuel Rail/System Pressure - Too High Fuel System Leak Detected - Large Leak Fuel Rail Pressure Sensor Circuit Malfunction Fuel Rail Pressure Sensor Circuit Low Input Fuel Rail Pressure Sensor Circuit High Input

Trouble Area Open or short in fuel pressure sensor circuit Fuel pressure sensor Engine ECU Short in supply pump (SCV) circuit Supply pump (SCV) Engine ECU High pressure fuel line Open or short in EDU circuit Open or short in injector circuit Supply pump Common-rail Injectors EDU Engine ECU Open or short in fuel pressure sensor circuit Fuel pressure sensor Engine ECU

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis DTCs for common-rail system

Trouble Area Detection Condition Fail-safe

DTC No. P0087 (49) P0088 (78) P0093 (78) P0190 (49) P0192 (49) P0193 (49)

Detection Item Fuel Rail/System Pressure - Too Low Fuel Rail/System Pressure - Too High Fuel System Leak Detected - Large Leak

Detection Condition Fuel pressure sensor output voltage stays at fixed value Fuel pressure exceeds predetermined value Difference of common-rail pressure before and after fuel injection varies greatly from difference of value that engine ECU calculates before and after injection

Fuel Rail Pressure Sensor Fuel pressure sensor output voltage is Circuit Malfunction 0.55V or less, or 4.9V or more for 0.5 sec. Fuel Rail Pressure Sensor Circuit Low Input Fuel Rail Pressure Sensor Circuit High Input Fuel pressure sensor output voltage is 0.55V or less for 0.5 sec. Fuel pressure sensor output voltage is 4.9V or more for 0.5 sec.

1 trip detection logic for all DTC

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis DTCs for common-rail system

Trouble Area Detection Condition Fail-safe

DTC No. P0087 (49) P0088 (78) P0093 (78) P0190 (49) P0192 (49) P0193 (49)

Detection Item Fuel Rail/System Pressure - Too Low Fuel Rail/System Pressure - Too High Fuel System Leak Detected - Large Leak Fuel Rail Pressure Sensor Circuit Malfunction Fuel Rail Pressure Sensor Circuit Low Input Fuel Rail Pressure Sensor Circuit High Input

Fail-safe

Limits engine power

Limits engine power for 1 min., and then stops the engine

Limits engine power

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis DTCs for common-rail system

Trouble Area Detection Condition Fail-safe

DTC No.

Detection Item

Trouble Area Open or short in EDU circuit EDU Injector Engine ECU

P0200 (97)

Injector Circuit / Open

P0627 (78)

Fuel Pump Control Circuit / Open

Open or short in (SCV) circuit SCV Engine ECU

Short in supply pump (SCV) circuit Supply pump (SCV) Engine ECU Injector compensation code Engine ECU

P1229 (78)

Fuel Pump System

P1601 (89)

Injector Correction Circuit Malfunction (EEPROM)

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis DTCs for common-rail system

Trouble Area Detection Condition Fail-safe

DTC No.

Detection Item

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. Fuel over-feed: Fuel pressure continues exceeding target fuel pressure despite engine ECU closing SCV Injector compensation code is not registered

P0200 (97)

Injector Circuit / Open

P0627 (78)

Fuel Pump Control Circuit / Open

P1229 (78)

Fuel Pump System

P1601 (89)

Injector Correction Circuit Malfunction (EEPROM)

1 trip detection logic for all DTC

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Diagnosis DTCs for common-rail system

Trouble Area Detection Condition Fail-safe

DTC No.

Detection Item

Fail-safe

P0200 (97)

Injector Circuit / Open

P0627 (78)

Fuel Pump Control Circuit / Open

Limits engine power

P1229 (78)

Fuel Pump System

P1601 (89)

Injector Correction Circuit Malfunction (EEPROM)

Common-rail System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Fuel Filter Replace fuel filter element only

Priming Pump Fuel Filter Warning Switch
To Supply Pump

From Fuel Tank

Fastener Nut Filter Housing (Plastic) Filter Element

Drain Cock

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Fuel Filter Construction

Priming Pump Fuel Filter Warning Switch

From Fuel Tank

To Supply Pump

Fastener Nut Filter Element Filter Housing (Plastic)

Fuel Sedimenter Level Warning Switch

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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 Fuel system warning light has been illuminated

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Fuel Warning System Fuel filter warning switch turns OFF when the filter outlet pressure decreases
Fuel Filter Warning Switch Fuel Filter Warning Switch

ON Meter
ECU
Diaphragm
To Supply Pump

OFF Meter
ECU

To Supply Pump

Filter Element

Negative Pressure

Normal Fuel Filter (Switch: ON)

Fuel Filter Clogged Up (Switch: OFF)

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Fuel Warning System Warning light condition for fuel filter / fuel sedimenter

Warning

Warning Method

Priority

Sedimenter Warning Blink Fuel Filter Warning ON

Fuel System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Charging System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Alternator Pulley In order to absorb a engine fluctuation, one-way clutch was adopted in the pulley

Spring

Roller

Charging System

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Alternator Pulley Engine fluctuation absorbing mechanism

One-way Clutch Locked
Crankshaft Pulley Speed

One-way Clutch Free

Alternator Pulley Speed Pulley Speed (rpm)

Engine Fluctuation

Time

Serpentine Belt Drive System

Serpentine Belt Drive Single V-ribbed belt
Air Conditioner Compressor Pulley

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Idler Pulley

Idler Pulley Alternator Pulley with Shock Absorbing Function

Water Pump Pulley

Idler Pulley for Automatic Tensioner

Crankshaft Pulley

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Reference

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Intake Shutter Valve Intake shutter valve position sensor

Magnet

Hall IC
Output Voltage (V) VC

3.51

Engine ECU

VLU

E2

20 0 (Full Close)

1 0.71 0

70 (Full Open)

100

Intake Shutter Valve Position Sensor

Intake Shutter Valve Opening Angle ()

Reference

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Variable Nozzle Vane Type Turbocharger (1KD only) Nozzle Vane Position Sensor Non-contact type position sensor
Hall ICs
Output characteristic of main, sub sensor Output Voltage (V) 4.5 2.5 0.5

Cross-section
0 -55

Magnets

55

-55

0 55 Sensor shaft rotation angle ()

Reference

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

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

Reference

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Fuel Cooler Construction

Fin

Cross Section

To Fuel Tank

From Supply Pump / Injector

Reference

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Accelerator Pedal Non-contact type accelerator pedal position sensor is used

Accelerator Pedal Position Sensor

Reference

Model Outline

KD Series Engine

Chassis

Body

Body Electrical

Accelerator Pedal Using magnet and hall IC

VCP1
Magnets VPA1 Output Voltage (V) EP1 VCP2 Hall IC VPA2 EP2 5 VPA2

VPA1
Full Open

Accelerator Pedal Position Sensor

Engine ECU

0 Full Close

Accelerator Pedal Depressed Angle