KD Engine Document: Model Outline for 1KD-FTV and 2KD-FTV Diesel Engines
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KD Engine Document: Model Outline for 1KD-FTV and 2KD-FTV Diesel Engines
- 1. Model Outline KD Series Engine Chassis Body Body Electrical Contents Click a Section Tab
- 2. 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 Control System
- 3. 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
- 4. Model Outline KD Series Engine Chassis Body Body Electrical Engine Overall 1KD-FTV / 2KD-FTV Specifications Item 1KD-FTV (HILUX, FORTUNER) 2KD-FTV (HILUX, FORTUNER, INNOVA) No. of Cylinders & Arrangement 4-Cylinder, In-line ← Valve Mechanism 16-Valve DOHC, Belt & Gear Drive ← Fuel System Common-Rail Type ← Intercooler With Without / With *2 Displacement cm3 (cu. in.) 2,982 (182.0) 2,492 (152.2) Bore x Stroke mm (in.) 96.0 x 103.0 (3.78 x 4.06) 92.0 x 93.8 (3.62 x 3.69) Compression Ratio 18.4 18.5 Max. Output kW @ rpm 120 @ 3,400 75 @ 3,600 88 @ 3,600 *2 Max. Torque N·m @ rpm 343 @1,400 ~ 3,200 200 @ 1,400 ~ 3,200 260 @ 1,600 ~ 2,400 *1 320 @ 2,000 *2 *1: 2KD-FTV High Version *2: 2KD-FTV High Version (HILUX for Thai only)
- 5. Model Outline KD Series Engine Chassis Body Body Electrical Engine Overall Features – Engine compartment Fuel Filter •Fuel filter warning (clogging detection) •Element replacing type SLLC Rotary Solenoid Type Diesel Throttle VN Type Turbocharger (1KD only) Photo: 1KD-FTV
- 6. Model Outline KD Series Engine Chassis Body Body Electrical Engine Overall Features – Under floor Fuel Cooler (with intercooler model only) Front
- 7. Model Outline KD Series Engine Chassis Body Body Electrical Valve Mechanism Timing Belt – Maintenance interval: replace at every 150,000 km Timing Belt Automatic Belt Tensioner Camshaft Timing Pulley No. 2 Camshaft Timing Pulley No. 1 Oil Pump Drive Gear Crankshaft Timing Gear Supply Pump Drive Gear Idle Gear Vacuum Pump Drive Gear
- 8. Model Outline 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 Cooler Oil Filter
- 9. Model Outline 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 Controls EGR amount Stop Full Close Reduced noise and vibration Rotary Solenoid type Motor Intake Shutter Valve Position Sensor Intake Shutter Valve Air flow
- 10. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Intake Shutter Valve – Construction Hall IC Magnet Magnet Steel Layer Magnet Intake Shutter Valve Position Sensor Rotary Solenoid Type Motor
- 11. Model Outline 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
- 12. Model Outline 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 Swirl Control Valve Intake Manifold Actuator VSV for SCV 1KD-FTV only
- 13. Model Outline KD Series Engine Chassis Body Body Electrical At low engine speed, SCV is closed to strengthen the swirl At low engine speed, SCV is closed to strengthen the swirl Intake and Exhaust System Swirl Control Valve (1KD only) – Operation Actuator Intake Air VSV Vacuum Pump Engine ECU Accelerator Pedal Opening Engine Speed ON / OFF
- 14. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Nozzle Vane is driven by DC motor DC Motor Link Turbine Wheel Full- Close Stopper Motor Rod Nozzle Vane Position Sensor
- 15. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Construction DC Motor Link Nozzle Vane Turbine Wheel Motor Rod Nozzle Vane Position Sensor Full- Close Stopper Intake Air Reduction Gears Exhaust Gas
- 16. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Construction Drive Arm Unison Ring Driven Arm Turbine Wheel Full-Close Stopper Link Motor Rod Nozzle Vane Gas Flow
- 17. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Feedback Control Nozzle Vane Position Turbo Motor Driver Target Angle Control StatusEngine ECU Turbo Pressure Sensor Atmospheric Temp. Sensor Atmospheric Pressure Sensor Water Temp. Sensor Injector (EDU) Crankshaft Position Sensor DC Motor Nozzle Vane Position Sensor Control
- 18. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Zero point calibration IG OFF → ON IG ON → OFF After the engine start Close Open Motor Rod Full-Close Stopper 0 Link 0 Link is bumped to full-close stopper Link is bumped to full-close stopper Zero point calibration Zero point calibration Nozzle vane is controlled based on the zero point Nozzle vane is controlled based on the zero point
- 19. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) – Operation movie Click! Movie
- 20. Model Outline 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
- 21. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Intercooler – Intake air is cooled in intercooler to increase the air density Turbocharger Thermal Expansion Contraction Increase oxygen densityOxygen
- 22. Model Outline KD Series Engine Chassis Body Body Electrical Intake and Exhaust System Intercooler – Intake air is cooled in intercooler to increase the air density
- 23. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System General Fuel Pressure Sensor EDU Pressure Limiter Supply Pump SCV Engine ECU Fuel Tank Injector NE Signal G Signal Various Signals Common-rail Fuel Cooler Pressure Switch Fuel Filter Fuel System Warning Light Other Injectors
- 24. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Features Fuel Pressure Sensor EDU Pressure Limiter Supply Pump SCV Engine ECU Fuel Tank Injector NE Signal G Signal Various Signals Common-rail Fuel Cooler Pressure Switch Fuel Filter Fuel System Warning Light Other Injectors Max. 160MPaMax. 160MPa HP3 Type Supply Pump HP3 Type Supply Pump Warning light for fuel filter clogging and fuel sedimenter Warning light for fuel filter clogging and fuel sedimenter Injector compensation code Injector compensation code Element replacement type Element replacement type Detects filter clogging Detects filter clogging Fuel cooler cools return fuel Fuel cooler cools return fuel
- 25. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System General – This system realize high injection pressure in all speed range of the engine Fuel Pressure Sensor Pressure Limiter Engine ECU Fuel Tank NE Signal G Signal Various Signals SCV Supply Pump (Generates high-pressure fuel) Common-rail Injector (Injects high-pressure fuel) EDU (Operates injector at high-speed) : High-pressure (Max. 160 MPa) (Stores high-pressure fuel)
- 26. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System System Outline System Common-rail Diesel Conventional Diesel 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 Pressure Sensor Constant high pressure ECU SCV Supply Pump Common-rail Injector Instantaneously high pressure Timer Governor Pump Injection Nozzle
- 27. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Location Common-rail •Fuel Pressure Sensor •Pressure LimiterSupply Pump •SCV (Suction Control Valve) •Fuel Temp. Sensor Injector Engine Front Injection Pipe Fuel Inlet Pipe
- 28. 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 From Fuel Filter (Inlet) To Common-rail (Outlet) To Fuel Tank (Return) SCV (Suction Control Valve)
- 29. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Construction Plunger Feed Pump Delivery Valve SCV (Suction Control Valve) Fuel Temp. Sensor Check Valve Eccentric and Ring Cam
- 30. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Construction Ring Cam Plunger Eccentric Cam To fuel tank (return)
- 31. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Fuel flow From fuel tank To common-rail
- 32. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Fuel flow (reference) Click! Movie
- 33. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Suction and pumping operation SCV : From Feed Pump : To Common-rail Plunger A: Suction Plunger B: Pumping Plunger A: Pumping Plunger B: Suction Plunger A Plunger B Check Valve
- 34. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Suction and pumping operation Click! Movie
- 35. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Fuel control operation (SCV opening small) Fuel Pumping Mass
- 36. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Fuel control operation (SCV opening large) Fuel Pumping Mass
- 37. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Fuel control operation (SCV opening small) Click! Movie
- 38. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Supply Pump – Fuel control operation (SCV opening large) Click! Movie
- 39. 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 Controls SCV opening Common-rail pressure (Feedback) Accelerator Pedal Position Sensor SCV Fuel Pressure Sensor Crankshaft Position Sensor Engine ECU Calculation of target injection pressure Calculation of target injection pressure [Fuel Pressure Control]
- 40. 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 From Supply Pump To Injector To Fuel Tank Fuel Pressure Sensor Pressure Limiter Common-rail
- 41. 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 Common-rail Pressure 0 190 1.0 4.04 Common-rail Pressure (MPa) OutputVoltage(V) Output characteristic Sensor Tip 90 2.44
- 42. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Injector – High pressure injection for higher atomization Injector Compensation Code From Common-rail Return to Fuel Tank ∅0.14 mm
- 43. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Injector – Construction Nozzle Needle Piston Solenoid Coil Return to Fuel Tank From Common-rail Nozzle Spring
- 44. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Injector – Controlled by engine ECU signal Solenoid Solenoid TWV Return From Common-rail Large Orifice Small Orifice Click! Movie
- 45. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Injector – Pilot injection reduces NOx and engine noise TDCTDC Pilot Injection Control Conventional Injection Control Pilot Main Heat Release Value Injection Volume NOx and engine noise
- 46. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Injector – Pilot injection reduces NOx and engine noise
- 47. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System EDU (Electronic Driver Unit) – Drive the injectors at high speed Engine ECU EDU Injector High Voltage DC / DC Converter DC / DC Converter Command Pulse Confirmation Pulse Battery IJT #1-4 IJF Control Circuit Control Circuit High-speed operation
- 48. Model Outline KD Series Engine Chassis Body Body Electrical Fail-safeDetection Condition Common-rail System Diagnosis – DTCs for common-rail system DTC No. Detection Item 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 • Open or short in fuel pressure sensor circuit •Fuel pressure sensor •Engine ECU P0192 (49) Fuel Rail Pressure Sensor Circuit Low Input P0193 (49) Fuel Rail Pressure Sensor Circuit High Input Trouble Area
- 49. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Diagnosis – DTCs for common-rail system DTC No. Detection Item 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. 1 trip detection logic for all DTC Detection Condition Fail-safeTrouble Area
- 50. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Diagnosis – DTCs for common-rail system DTC No. Detection Item Fail-safe P0087 (49) Fuel Rail/System Pressure - Too Low Limits engine power P0088 (78) Fuel Rail/System Pressure - Too High P0093 (78) Fuel System Leak Detected - Large Leak Limits engine power for 1 min., and then stops the engine P0190 (49) Fuel Rail Pressure Sensor Circuit Malfunction Limits engine power P0192 (49) Fuel Rail Pressure Sensor Circuit Low Input P0193 (49) Fuel Rail Pressure Sensor Circuit High Input Trouble Area Fail-safeDetection Condition
- 51. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Diagnosis – DTCs for common-rail system DTC No. Detection Item Trouble Area P0200 (97) Injector Circuit / Open •Open or short in EDU circuit •EDU •Injector •Engine ECU P0627 (78) Fuel Pump Control Circuit / Open •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 Fail-safeTrouble Area Detection Condition
- 52. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Diagnosis – DTCs for common-rail system DTC No. Detection Item Detection Condition P0200 (97) Injector Circuit / Open 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 P0627 (78) Fuel Pump Control Circuit / Open 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 1 trip detection logic for all DTC Detection ConditionTrouble Area Fail-safe
- 53. Model Outline KD Series Engine Chassis Body Body Electrical Common-rail System Diagnosis – DTCs for common-rail system DTC No. Detection Item Fail-safe P0200 (97) Injector Circuit / Open Limits engine powerP0627 (78) Fuel Pump Control Circuit / Open P1229 (78) Fuel Pump System P1601 (89) Injector Correction Circuit Malfunction (EEPROM) - Fail-safeDetection ConditionTrouble Area
- 54. 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
- 55. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Filter – Replace fuel filter element only Fuel Filter Warning Switch From Fuel Tank To Supply Pump Priming Pump Filter Housing (Plastic) Fastener Nut Drain Cock Filter Element
- 56. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Filter – Construction Filter Element Fuel Filter Warning Switch From Fuel Tank To Supply Pump Priming Pump Fuel Sedimenter Level Warning Switch Filter Housing (Plastic) Fastener Nut
- 57. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Warning System – Fuel filter clogging is detected by fuel filter warning switch Combination Meter Fuel Filter Warning Switch Fuel System Warning Light Fuel Filter - Fuel Filter Maintenance Interval - Fuel system warning light has been illuminated Cloggin g
- 58. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Warning System – System Diagram Combination Meter Fuel Filter Warning Switch Meter ECU Filter Element Fuel System Warning Light To Supply Pump Vehicle Speed Sensor Fuel Sedimenter Level Warning SwitchFuel Filter
- 59. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Warning System – Fuel filter warning switch turns OFF when the filter outlet pressure decreases Fuel Filter Warning Switch To Supply Pump Filter Element Normal Fuel Filter (Switch: ON) Fuel Filter Clogged Up (Switch: OFF) Diaphragm ON Meter ECU Fuel Filter Warning Switch To Supply Pump OFF Meter ECU Negative Pressure
- 60. 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 Priority Sedimenter Warning Blink 1 Fuel Filter Warning ON 2
- 61. Model Outline KD Series Engine Chassis Body Body Electrical Fuel System Fuel Warning System – Detection conditions OFF for 10 min. or more OFF for 10 min. or more OFF is detected for 2 times during 1 trip OFF is detected for 2 times during 1 trip After the driving for 30 min. or moreAfter the driving for 30 min. or more The warning light keeps ON until the reset operation is done Fuel Filter Warning Switch Condition or
- 62. 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 RollerSpring
- 63. Model Outline KD Series Engine Chassis Body Body Electrical Charging System Alternator Pulley – Engine fluctuation absorbing mechanism Engine Fluctuation Alternator Pulley Speed Crankshaft Pulley Speed PulleySpeed(rpm) Time One-way Clutch Locked One-way Clutch Free
- 64. Model Outline KD Series Engine Chassis Body Body Electrical Serpentine Belt Drive System Serpentine Belt Drive – Single V-ribbed belt Alternator Pulley with Shock Absorbing Function Water Pump Pulley Air Conditioner Compressor Pulley Idler Pulley for Automatic Tensioner Idler Pulley Idler Pulley Crankshaft Pulley
- 65. Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System Oil Maintenance Management System – This system determines the deterioration conditions of the engine oil
- 66. Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System Oil Maintenance Management System – System diagram and general operation Soot Volume ODO / TRIP Switch Engine ECU Engine Oil Change Reminder Light •Engine Speed •Injection Volume •Injection Timing •A/F Ratio •Engine Speed •Injection Volume •Injection Timing •A/F Ratio Meter ECU Vehicle Speed Blink or ON Soot Volume Calculation Soot Volume Calculation
- 67. Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System Oil Maintenance Management System – Soot calculating logic A/F Ratio Injection End Timing Soot Volume Rich Lean Retard Advance
- 68. Model Outline KD Series Engine Chassis Body Body Electrical Engine Control System Oil Maintenance Management System – Engine oil change reminder light operation Condition Engine Oil Change Reminder Light Mileage = 35,000 km ~ 40,000 km or Specified Soot Volume A Mileage = 40,000 km or more or Specified Soot Volume B
- 69. Model Outline KD Series Engine Chassis Body Body Electrical
- 70. Model Outline KD Series Engine Chassis Body Body Electrical Reference Intake Shutter Valve – Intake shutter valve position sensor Intake Shutter Valve Opening Angle (°) OutputVoltage(V) 0 Engine ECU VC VLU Hall IC Magnet E2 0 (Full Close) 70 (Full Open) Intake Shutter Valve Position Sensor 1 5 0.71 20 100 3.51
- 71. 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 0-55 55 0.5 2.5 4.5 Sensor shaft rotation angle (°) OutputVoltage(V) Output characteristic of main, sub sensor VN Close VN Open -55 ° 55 ° Hall ICs Magnets Cross-section 0 °
- 72. 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 From Supply Pump / Injector To Fuel Tank Fuel Cooler (Aluminum) Front
- 73. Model Outline KD Series Engine Chassis Body Body Electrical Reference Fuel Cooler – Construction From Supply Pump / Injector To Fuel Tank Cross Section Fin
- 74. 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
- 75. Model Outline KD Series Engine Chassis Body Body Electrical Reference Accelerator Pedal – Using magnet and hall IC Accelerator Pedal Depressed Angle Full OpenFull Close VPA1 VPA2 OutputVoltage(V) 0 5 VCP1 VCP2 VPA2 VPA1 Hall IC Magnets EP1 EP2 Engine ECU Accelerator Pedal Position Sensor
Editor's Notes
- TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine)
- Intercooler has been adopted on 1KD-FTV engine and it realizes higher output and torque Each of the 2KD-FTV engine and the 2KD-FTV engine (High Version) is controlled by the different programmed engine ECU to tune their output and torque
- SLLC Maintenance Interval - Inspect at every 40,000km First replace at 160,000km, then replace at every 80,000km Rotary solenoid type D-throttle VN(Variable Nozzle vane) type turbocharger Fuel filter -Filter warning for maintenance -Element replacing type
- A fuel cooler cools the return fuel It is adopted only for models with intercooler Injection pressure: With intercooler model Max. 160 MPa Without intercooler model Max. 135 MPa
- 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
- Maintenance interval: replace at every 150,000 km
- -Rotary solenoid realizes linear control D-throttle -At the engine starting: full open -At the engine stop: full close -During the engine operation: Linear control between small and full open to ensure driving condition and EGR performance to make vacuum in intake manifold
- A quick response and high precise control are realized by driving a valve shaft directly Full Open Full Close: 100 ms
- Two different shape of intake port in each cylinder to make optimized swirl in cylinder
- -1KD-FTV engine equips swirl control valve in one of the intake ports in each cylinder -This system makes strong swirl in cylinder to promotes air-fuel mixture for better combustion
- -The Valve is controlled by the engine ECU through VSV -Operating condition of the valve Low engine speed: close to strengthen the swirl in the combustion chamber High engine speed: open Cold engine start: open to reduce the white smoke
- -Variable nozzle vane type turbocharger(1KD-FTV only) to ensure higher effectiveness in full range -Water-cooled type
- The system is controlled by engine ECU and nozzle vane is regulated by DC motor
- Depending on the engine speed, angle of vane is changed At low engine speed, vane is turned and exhaust gas is effectively applied to turbine
- Engine ECU always detects and controls the vane optimally
- -The motor rod position is calibrated as zero point when IG is turned -Nozzle vane is controlled based on the sensor zero point -Don’t tighten or loosen the Full-Close Stopper lock nut
- Don’t tighten or loosen the full-close stopper lock nut After the replacement or reinstallation of the turbocharger, perform the operation check before engine starting
- Air-cooled type
- After turbocharger, heated intake air is cooled down to increase the air density. Thus, engine outputs higher power and torque
- After turbocharger, heated intake air is cooled down to increase the air density. Thus, engine outputs higher power and torque
- Common-rail Diesel system -Higher output -Low noise and vibration -Cleaner emission
- Features -Two opposed type (HP3) supply pump -Higher pressure fuel (160 MPa) -QR type Injector compensation -Fuel filter warning system with segimenter -Fuel filter element replacement -Fuel cooler
- - Common-rail Pressure - 1KD, 2KD with Intercooler: 30 – 160 MPa (306 – 1632 kgf/cm2, 4351 – 23206 psi) 2KD without Intercooler: 30 – 135 MPa (306 – 1377 kgf/cm2, 4351 – 19580 psi)
- 160 MPa = 1632 kgf / cm2 = 23206 psi 15 MPa = 153 kgf / cm2 = 2176 psi
- HP3 type supply pump is compact and light weight design
- 2-plunger, opposite type
- SCV adjusts fuel volume supplied to common rail and regulates internal fuel pressure
- SCV adjusts fuel volume supplied to common rail and regulates internal fuel pressure
- Engine ECU calculates the target injection pressure (Max. 160 MPa) based on the signals from the acceleration pedal position sensor and the crankshaft position sensor (Driving condition) Engine ECU controls the SCV opening to regulate the pumping volume, so that the pressure detected by the fuel pressure sensor matches the target injection pressure - Common-rail Pressure (Target Injection Pressure) - 1KD, 2KD with Intercooler: 30 – 160 MPa (306 – 1632 kgf/cm2, 4351 – 23206 psi) 2KD without Intercooler: 30 – 135 MPa (306 – 1377 kgf/cm2, 4351 – 19580 psi)
- Pressure Limiter: Relief the fuel when pressure rises abnormally high (200 MPa) Discharge valve is discontinued from previous 2KD-FTV
- Small injection hole (0.14 mm) 1KD-FTV: 8-hole type 2KD-FTV: 6-hole type
- Small injection hole (0.14 mm)
- No Injection -Solenoid is not energized and the TWV is closed by spring and fuel pressure. Nozzle also closes by high pressure fuel in chamber Injection Start -Solenoid operates to open TWV. Then, fuel starts to flow out of the control chamber through large orifice. -Nozzle needle rises and injection starts. -The orifice also causes the injection rate to increase gradually. Injection End -Solenoid is finished to energized and TWV is closed by the valve spring and fuel pressure. -High-pressure fuel is applied in chamber -Nozzle is closed rapidly, and sharp injection end is realized.
- Pilot injection -Inject small amount of fuel initially before main injection timing -It shortens ignition delay at the main injection -It reduces noise, vibration and emission by preventing sudden rising of combustion pressure in cylinder
- Pilot injection -Inject small amount of fuel initially before main injection timing -It shortens ignition delay at the main injection -It reduces noise, vibration and emission by preventing sudden rising of combustion pressure in cylinder
- -EDU converts to high voltage signal by receiving the injection signal from engine ECU to realizes high response operation. -EDU outputs confirmation signal (IJF) to engine ECU to detect operation condition
- -Initialization and calibration are required after replacement of supply pump or engine ECU. -Engine ECU learns and memorizes the supply pump discharge volume variances
- [Initialization (not using IT II)] 1, Short the TC and CG terminals of DLC3 2, IG ON 3, Wait for 3 min. 4, IG OFF NOTE: Initialization is needed only when the engine can not start after replacement When using IT II, perform the “Supply Pump Initialization” [Calibration] 1, Start and warm-up the engine (until the engine coolant temp.[THW] more than 60 °C and fuel temp.[THF] more than 20°C) (THW > 60°C = Thermostat open) (THF > 20°C = Ambient temperature > 20°C) NOTE: When using IT II, check the THW and THF value by data list 2, Idling for 1 min. after the warm-up 3, IG OFF
- NOTE: If disassembled, change common-rail assembly
- -Injector replacement: New injector’s compensation value should be reprogrammed in engine ECU -Engine ECU is changed: All of the existing injector compensation codes must be input to new engine ECU.
- After replacement of engine ECU or injector, DTC P1601 is set
- NOTE: Before replacement of engine ECU, injector compensation code for all injectors should be saved in the Intelligent Tester II
- After replacement, reprogram injector compensation code which are saved
- NOTE: Non reusable parts.
- Without Intelligent Tester II [ Perform Fuel Leak Teat (Active Test) ] -Fully depress the accelerator pedal quickly -Make maximum engine speed and keep it for 2 sec. -Repeat this operation several times
- CAUTION: Do not disconnect the injector connector while engine running because of high voltage
- Fuel filter type is changed from cartridge type to element only
- Fuel filter warning is added. Basic construction is same as previous diesel engine system. -Sedimenter level warning system -Priming pump
- Fuel filter maintenance timing: Fuel system warning light in combination meter turns on when filter replacement is required. ***This warning light is for both filter warning and sedimenter warning
- Fuel filter warning: filter clogging detection Sedimenter warning: water level detection by float system
- -Fuel filter clogging system: Vacuum type sensor -Filter element is clogged, suction from supply pump generates higher negative pressure in fuel pipe. Then, switch is turned off.
- Warning condition: -Sedimenter warning: blink -Fuel filter warning: stays on If the both sedimenter and fuel filter warning are detected, the warning light blinks (as sedimenter warning)
- To prevent false alarms on a cold engine, the meter ECU starts its judgment function after the driving for 30 min. or mode Fuel Filter Warning Detection Conditions - Fuel filter warning switch is OFF for 10 min. or more - Fuel filter warning switch OFF is detected for 2 times during 1 trip (OFF for 1 sec. or more = 1 time)
- Fuel Filter Maintenance Change fuel filter element
- Removal: 1, Disconnect battery negative terminal 2, Loosen the fuel cap (reduce tank pressure) 3, Disconnect the fuel filter warning switch connector 4, Disconnect the hose connected to the filter inlet side 5, Connect the hose to drain cock and drain fuel inside (approx. 50 cc)
- 6, Loosen the fastener nut using screwdriver, and fully loosen by hand
- 7, Remove the filter cap 8, Remove the filter element from the case 9, Remove O-ring Installation: 1, Attach 3 new O-rings to new element and the case
- 2, Install new filter element and cover the filter cap to the case NOTE: Align match mark 3, Tighten the fastener nut NOTE: Tighten the nut until match mark is aligned
- 4, Connect the hose to the filter inlet side 5, Tighten the fuel cap 6, Connect battery negative terminal ***NOT connect the fuel filter warning switch connector
- Reset Operation: IG ON (The fuel filter warning switch connector should be disconnected before IG ON) Connect the fuel filter warning switch connector 3 – 60 sec. after IG ON 3 sec. after the step2, fuel system warning light is turned OFF (Completion of the reset)
- After replacement of the filter, bleed the air in fuel system by priming pump
- A compact and lightweight segment conductor type alternator (SE08 type)
- Oil maintenance management system is used only for Europe models
- The soot volume and mileage is memorized in the meter ECU
- [Engine oil change reminder light operation] Blink: Mileage = 35,000 km ~ 40,000 km or attains specified soot volume A Illuminate: Mileage = 40,000 km or more or attains specified soot volume B - The mileage from reset operation - The specified soot volume A is approx. 80% of specified soot volume B
- Perform the reset operation after the replacement of the engine oil The accumulated soot volume and mileage data memorized in the meter ECU can be reset by the reset operation
- [Reset Operation] 1, IG ON 2, LCD display is in the TRIP A 3, IG OFF 4, While pressing the ODO / TRIP switch, turn to IG ON 5, Hold the ODO / TRIP switch down for more than 5 sec.
- 6, Engine oil change reminder light is turned off (LCD display indicates “000000” for about 1 sec.) HINT: Meter ECU is resetting the soot volume and mileage data at “000000” display 7, LCD displays TRIP A 8, Release the ODO / TRIP switch
- Sensor uses hall IC as no contact type to ensure its durability and reliability
- Vane angle is detected by its position sensor with hall IC as non contact type
- Fuel cooler cools the return fuel from engine Fuel cooler with intercooler model only