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Contents
KD Series Engine
Chassis
Body
Body Electrical
Model Outline
KD Series Engine
Chassis
motor general
Mecanismo de vlvula
Sistema de lubricacin
Sistema Admisin y de escape
Sistema Common-rail
Sistema de combustible
Sistema de carga
Serpentina Sistema de correa de
transmisin
Body
Body Electrical
Model Outline
KD Series Engine
Engine Overall
Chassis
Body
Body Electrical
1KD-FTV / 2KD-FTV
TOYOTA D-4D, 3.0 / 2.5 liter, in-line 4-cilindros
, 16 valve DOHC con motor diesel turboalimentado
1KD-FTV
2KD-FTV
Model Outline
KD Series Engine
Engine Overall
Chassis
Body
Body Electrical
1KD-FTV
(HILUX)
2KD-FTV
(HILUX, INNOVA)
4-Cilindros en Linea
16-Valve DOHC,
Correa y la transmisin de
engranajes
Tipo Common-Rail
With
Without / With *2
2,982 (182.0)
2,492 (152.2)
96.0 x 103.0
(3.78 x 4.06)
92.0 x 93.8
(3.62 x 3.69)
Relacin de compresin
18.4
18.5
120 @ 3,400
75 @ 3,600
88 @ 3,600 *2
Intercooler
desplazamiento
Max. Torque
Nm @ rpm
Model Outline
KD Series Engine
Engine Overall
Chassis
Body
Body Electrical
caractersticas
compartimiento del motor
Rotary Solenoid Type
Diesel Throttle
VN Type Turbocharger
(1KD only)
Photo: 1KD-FTV
SLLC
Fuel Filter
Model Outline
KD Series Engine
Engine Overall
Features
Under floor
Front
Chassis
Body
Body Electrical
Fuel Cooler
(with intercooler model only)
Model Outline
KD Series Engine
Engine Proper
Chassis
Body
Body Electrical
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
Valve Mechanism
Chassis
Body
Body Electrical
Timing Belt
Maintenance interval: replace at every 150,000 km
Camshaft
Timing
Pulley No. 2
Timing
Belt
Automatic
Belt
Tensioner
Camshaft
Timing
Pulley No. 1
Model Outline
KD Series Engine
Lubrication System
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
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
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
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Rotary Solenoid
Type Motor
Steel Layer
Magnet
Hall IC
Magnet
Magnet
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
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Actuator
1KD-FTV only
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Intake
Air
At
At low
low engine
engine speed,
speed,
SCV
is
closed
SCV is closed to
to
strengthen
the
swirl
strengthen the swirl
Actuator
Vacuum
Pump
VSV
Engine Speed
ON / OFF
Engine
ECU
Accelerator
Pedal Opening
Model Outline
Chassis
KD Series Engine
Body
Body Electrical
Nozzle Vane
Position Sensor
Turbine
Wheel
Motor Rod
Link
FullClose
Stopper
Model Outline
Chassis
KD Series Engine
Body
Body Electrical
DC Motor
Intake Air
Nozzle Vane
Position Sensor
Turbine
Wheel
Reduction
Gears
Motor Rod
Link
Nozzle Vane
FullClose
Stopper
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Gas Flow
Drive Arm
Turbine
Wheel
Link
Unison Ring
Nozzle
Vane
Driven Arm
Full-Close Stopper
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Target Angle
Engine
ECU
Atmospheric
Pressure
Sensor
Control Status
Turbo Motor
Driver
Control
Nozzle
Vane
Position
DC
Motor
Nozzle
Vane
Position
Sensor
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
ON OFF
Link is bumped
to full-close
stopper
IG
Zero point
calibration
OFF ON
Motor Rod
Open
Close
After the
engine
start
Nozzle vane is
controlled based
on the zero point
Link
Full-Close
Stopper
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Click!
Movie
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Waste Gate
Valve
Actuator
for Waste
Gate Valve
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Intercooler
Intake air is cooled in intercooler to increase the air
density
Thermal
Expansion
Oxygen
Turbocharger
Increase
oxygen density
Contraction
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Intercooler
Intake air is cooled in intercooler to increase the air
density
Model Outline
Chassis
KD Series Engine
Fuel System
Body
Body Electrical
General
NE Signal
Engine
ECU
G Signal
EDU
Various
Signals
Other Injectors
Fuel Pressure
Sensor
Pressure
Limiter
Common-rail
Injector
Pressure
Switch
Fuel Cooler
SCV
Supply Pump
Fuel System
Warning Light
Fuel
Filter
Fuel Tank
Model Outline
Chassis
KD Series Engine
Fuel System
Body
Body Electrical
Features
NE Signal
Engine
ECU
G Signal
Various
Signals
EDU
Other Injectors
Max.
Max. 160MPa
160MPa
HP3
HP3 Type
Type
Fuel Pressure
Supply
Supply Sensor
Pump
Pump
Injector
Injector
compensation
compensation
code
code
Pressure
Limiter
Common-rail
Injector
Pressure
Switch
Fuel Cooler
Warning
Warning
Supplylight
light
Pump
for
for fuel
fuel filter
filter
clogging
clogging and
and
fuel
fuel sedimenter
sedimenter
SCV
Fuel
Filter
Fuel System
WarningDetects
Light
Detects
filter
filter
clogging
clogging
Element
replacement
replacement
type
type
Element
Fuel Tank
Fuel
Fuel cooler
cooler
cools
cools return
return
fuel
fuel
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
System Outline
Common-rail Diesel
Constant high pressure
Pressure
Common-rail
Sensor
System
SCV
Conventional Diesel
Instantaneously high pressure
Governor
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
Pressurization
Supply Pump
Pump
Distribution
Common-rail
Pump
Injection Pressure
Approx. 15 MPa
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Location
Engine
Front
Injection Pipe
Injector
Common-rail
Supply Pump
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Construction
Check
Valve
Eccentric and
Ring Cam
Plunger
Delivery
Valve
Feed
Pump
Fuel Temp.
Sensor
SCV (Suction
Control Valve)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Construction
To fuel tank (return)
Ring Cam
Plunger
Eccentric
Cam
Model Outline
KD Series Engine
Common-rail System
Supply Pump
Fuel flow
Chassis
To common-rail
From fuel
tank
Body
Body Electrical
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Supply Pump
Fuel flow (reference)
Click!
Movie
Body Electrical
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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
: To Common-rail
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Suction and pumping operation
Click!
Movie
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Fuel control operation (SCV opening small)
Fuel
Pumping
Mass
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Fuel control operation (SCV opening large)
Fuel
Pumping
Mass
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Fuel control operation (SCV opening small)
Click!
Movie
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
Fuel control operation (SCV opening large)
Click!
Movie
Model Outline
KD Series Engine
Common-rail System
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
Engine ECU
Crankshaft
Position Sensor
Accelerator Pedal
Position Sensor
Model Outline
KD Series Engine
Common-rail System
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Common-rail
Fuel pressure sensor
Detects the internal fuel pressure of common-rail
Output characteristic
Output Voltage (V)
Sensor Tip
4.04
2.44
1.0
0
90
190
Common-rail Pressure (MPa)
Common-rail
Pressure
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Injector
High pressure injection for higher atomization
Return to
Fuel Tank
From
Common-rail
Injector
Compensation
Code
0.14 mm
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Injector
Construction
Solenoid Coil
Return to
Fuel Tank
From
Common-rail
Piston
Nozzle
Spring
Nozzle
Needle
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
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
Common-rail System
Chassis
Body
Body Electrical
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Injector
Pilot injection reduces NOx and engine noise
Body Electrical
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
EDU
Battery
DC / DC
Converter
Command
Pulse
IJT
#1-4
IJF
Engine
ECU
Confirmation
Pulse
Control
Circuit
High
Voltage
High-speed
operation
Injector
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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
P0088
(78)
Fuel Rail/System
Pressure - Too High
P0093
(78)
P0190
(49)
P0192
(49)
P0193
(49)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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
P0088
(78)
Fuel Rail/System
Pressure - Too High
P0093
(78)
P0190
(49)
P0192
(49)
P0193
(49)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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)
P0190
(49)
P0192
(49)
P0193
(49)
Detection Condition
Fail-safe
Fail-safe
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Trouble Area
P0200
(97)
P0627
(78)
P1229
(78)
P1601
(89)
Injector Correction
Circuit Malfunction
(EEPROM)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Detection Condition
P0200
(97)
P0627
(78)
P1229
(78)
Fuel over-feed:
Fuel pressure continues exceeding target
fuel pressure despite engine ECU closing
SCV
P1601
(89)
Injector Correction
Circuit Malfunction
(EEPROM)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
P0200
(97)
P0627
(78)
P1229
(78)
P1601
(89)
Injector Correction
Circuit Malfunction
(EEPROM)
Detection Condition
Fail-safe
Fail-safe
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Filter
Replace fuel filter element only
Priming
Pump
Fuel Filter
Warning Switch
To Supply Pump
Fastener Nut
Filter Housing
(Plastic)
Filter Element
Drain Cock
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Filter
Construction
Priming
Pump
Fuel Filter
Warning Switch
To Supply Pump
Fastener Nut
Filter Element
Filter Housing
(Plastic)
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel System
Warning Light
Cloggin
g
Combination Meter
Fuel Filter
- Fuel Filter Maintenance Interval Fuel system warning light has been illuminated
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Meter
ECU
Fuel System
Warning Light
To Supply Pump
Filter Element
Fuel Filter
Model Outline
Chassis
KD Series Engine
Fuel System
Body
Body Electrical
ON Meter
ECU
Fuel Filter
Warning
Switch
OFF Meter
ECU
Diaphragm
To Supply Pump
Filter Element
To Supply Pump
Negative
Pressure
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Warning
Warning
Method
Sedimenter
Warning
Priority
1
Blink
Fuel Filter
Warning
2
ON
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
or
OFF
OFF is
is detected
detected for
for 22
times
times during
during 11 trip
trip
Model Outline
KD Series Engine
Charging System
Chassis
Body
Body Electrical
Alternator Pulley
In order to absorb a engine fluctuation, one-way
clutch was adopted in the pulley
Spring
Roller
Model Outline
KD Series Engine
Charging System
Chassis
Body
Body Electrical
Alternator Pulley
Engine fluctuation absorbing mechanism
One-way
Clutch
Locked
Crankshaft Pulley
Speed
One-way
Clutch
Free
Alternator
Pulley Speed
Engine
Fluctuation
Time
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Idler Pulley
Idler Pulley
Water Pump
Pulley
Alternator Pulley
with Shock
Absorbing Function
Crankshaft Pulley
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Magnet
Output Voltage (V)
Hall IC
VC
Engine
ECU
VLU
E2
5
3.51
1
0.71
0
20
0
(Full Close)
Intake Shutter
Valve Position
Sensor
70
(Full Open)
100
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Magnets
Cross-section
0
-55
55
Output characteristic of
main, sub sensor
4.5
pe
O
VN
2.5
0.5
-55
Cl o
N
V
se
0
55
Sensor shaft rotation angle ()
Model Outline
Reference
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
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Fuel Cooler
Construction
Fin
Cross
Section
To Fuel Tank
From
Supply Pump / Injector
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Accelerator Pedal
Non-contact type accelerator pedal position sensor is
used
Accelerator Pedal
Position Sensor
Model Outline
Reference
Chassis
Body
Body Electrical
Accelerator Pedal
Using magnet and hall IC
VCP1
Magnets
VPA1
Output Voltage (V)
KD Series Engine
EP1
VCP2
Hall
IC
VPA2
EP2
Accelerator
Pedal Position
Sensor
Engine
ECU
5
VPA2
VPA1
0
Full Close
Full Open