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Contents

Click a Section Tab. Contents. 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. Engine Overall. 1KD-FTV / 2KD-FTV

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Contents

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  1. Click a Section Tab Contents

  2. 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. 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. Engine Overall • 1KD-FTV / 2KD-FTV Specifications *1: 2KD-FTV High Version *2: 2KD-FTV High Version (HILUX for Thai only)

  5. Engine Overall • Features • Engine compartment Rotary Solenoid Type Diesel Throttle VN Type Turbocharger (1KD only) Photo: 1KD-FTV • Fuel Filter • Fuel filter warning (clogging detection) • Element replacing type SLLC

  6. Engine Overall • Features • Under floor Fuel Cooler (with intercooler model only) Front

  7. 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

  8. Valve Mechanism • Timing Belt • Maintenance interval: replace at every 150,000 km Oil Pump Drive Gear Camshaft Timing Pulley No. 2 Crankshaft Timing Gear Supply Pump Drive Gear Timing Belt Automatic Belt Tensioner Camshaft Timing Pulley No. 1 Vacuum Pump Drive Gear Idle Gear

  9. Lubrication System • Lubrication System • Overall • Lubrication is fully pressurized and all oil passes through an oil cooler and oil filter Oil Filter Oil Cooler

  10. Intake and Exhaust System • Intake Shutter Valve • Rotary solenoid type intake shutter valve is used to improve EGR performance Intake Shutter Valve Position Sensor Air flow Intake Shutter Valve Rotary Solenoid type Motor

  11. Intake and Exhaust System • Intake Shutter Valve • Construction Rotary Solenoid Type Motor Intake Shutter Valve Position Sensor Steel Layer Magnet Hall IC Magnet Magnet

  12. Intake and Exhaust System • Intake Manifold • Two intake port with different shape from intake manifold to cylinder head • For swirl optimizing in cylinder

  13. 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

  14. Intake and Exhaust System • Swirl Control Valve (1KD only) • Operation Intake Air At low engine speed, SCV is closed to strengthen the swirl Vacuum Pump Actuator Engine Speed Engine ECU VSV ON / OFF Accelerator Pedal Opening

  15. 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 Full-Close Stopper

  16. 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 Full-Close Stopper Nozzle Vane

  17. 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

  18. Intake and Exhaust System • Variable Nozzle Vane Type Turbocharger (1KD only) • Feedback Control Engine ECU Injector (EDU) Target Angle Turbo Motor Driver Crankshaft Position Sensor Control Status Nozzle Vane Position Turbo Pressure Sensor Control Atmospheric Temp. Sensor Atmospheric Pressure Sensor DC Motor Water Temp. Sensor Nozzle Vane Position Sensor

  19. 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 Nozzle vane is controlled based on the zero point After the engine start Full-Close Stopper 0

  20. Click! Movie Intake and Exhaust System • Variable Nozzle Vane Type Turbocharger (1KD only) • Operation movie

  21. Intake and Exhaust System • Turbocharger (2KD only) • Light weight, compact and high performance turbocharger Waste Gate Valve Actuator for Waste Gate Valve

  22. Intake and Exhaust System • Intercooler • Intake air is cooled in intercooler to increase the air density Thermal Expansion Contraction Increase oxygen density Oxygen Turbocharger

  23. Intake and Exhaust System • Intercooler • Intake air is cooled in intercooler to increase the air density

  24. NE Signal G Signal Various Signals Fuel System • General Engine ECU EDU Other Injectors Pressure Limiter Fuel Pressure Sensor Common-rail Injector Pressure Switch Fuel Cooler Fuel Filter SCV Fuel System Warning Light Supply Pump Fuel Tank

  25. Injector compensation code NE Signal Max. 160MPa HP3 Type Supply Pump G Signal Various Signals Fuel cooler cools return fuel Warning light for fuel filter clogging and fuel sedimenter Element replacement type Detects filter clogging Fuel System • Features Engine ECU EDU Other Injectors Pressure Limiter Fuel Pressure Sensor Common-rail Injector Pressure Switch Fuel Cooler Fuel Filter SCV Fuel System Warning Light Supply Pump Fuel Tank

  26. NE Signal G Signal Various Signals Common-rail System • General • This system realize high injection pressure in all speed range of the engine EDU (Operates injector at high-speed) Engine ECU Pressure Limiter Fuel Pressure Sensor 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)

  27. Constant high pressure Instantaneously high pressure Pressure Sensor Common-rail Governor SCV Timer ECU Injection Nozzle Injector Pump Supply Pump Common-rail System • System Outline

  28. Common-rail System • Location Engine Front Injection Pipe Injector Fuel Inlet Pipe • Common-rail • Fuel Pressure Sensor • Pressure Limiter • Supply Pump • SCV (Suction Control Valve) • Fuel Temp. Sensor

  29. Common-rail System • 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)

  30. Common-rail System • Supply Pump • Construction Eccentric and Ring Cam Delivery Valve Check Valve Plunger Feed Pump Fuel Temp. Sensor SCV (Suction Control Valve)

  31. Common-rail System • Supply Pump • Construction To fuel tank (return) Ring Cam Plunger Eccentric Cam

  32. Common-rail System • Supply Pump • Fuel flow To common-rail From fuel tank

  33. Click! Movie Common-rail System • Supply Pump • Fuel flow (reference)

  34. Common-rail System • Supply Pump • Suction and pumping operation Plunger A: SuctionPlunger B: Pumping Plunger A: PumpingPlunger B: Suction Check Valve Plunger A SCV Plunger B : From Feed Pump : To Common-rail

  35. Click! Movie Common-rail System • Supply Pump • Suction and pumping operation

  36. Common-rail System • Supply Pump • Fuel control operation (SCV opening small) Fuel Pumping Mass

  37. Common-rail System • Supply Pump • Fuel control operation (SCV opening large) Fuel Pumping Mass

  38. Click! Movie Common-rail System • Supply Pump • Fuel control operation (SCV opening small)

  39. Click! Movie Common-rail System • Supply Pump • Fuel control operation (SCV opening large)

  40. Common-rail System • Supply Pump • The SCV opening regulates the pumping volume to control fuel pressure [Fuel Pressure Control] Fuel Pressure Sensor Common-rail pressure (Feedback) SCV Controls SCV opening Crankshaft Position Sensor Calculation of target injection pressure Accelerator Pedal Position Sensor Engine ECU

  41. Common-rail System • Common-rail • Stores high-pressure fuel (Max. 160 MPa) produced by supply pump Pressure Limiter Fuel Pressure Sensor Common-rail FromSupply Pump To Injector To Fuel Tank

  42. Common-rail System • Common-rail • Fuel pressure sensor • Detects the internal fuel pressure of common-rail Output characteristic Sensor Tip 4.04 2.44 Output Voltage (V) 1.0 0 90 190 Common-rail Pressure (MPa) Common-rail Pressure

  43. Common-rail System • Injector • High pressure injection for higher atomization Injector Compensation Code FromCommon-rail Return toFuel Tank 0.14 mm

  44. Common-rail System • Injector • Construction Solenoid Coil FromCommon-rail Return toFuel Tank Piston Nozzle Spring Nozzle Needle

  45. Click! Movie Common-rail System • Injector • Controlled by engine ECU signal Solenoid Solenoid TWV Small Orifice Return From Common-rail Large Orifice

  46. Common-rail System • Injector • Pilot injection reduces NOx and engine noise Main Pilot Injection Volume NOx and engine noise Heat Release Value TDC TDC Conventional Injection Control Pilot Injection Control

  47. Common-rail System • Injector • Pilot injection reduces NOx and engine noise

  48. Common-rail System • EDU (Electronic Driver Unit) • Drive the injectors at high speed EDU Battery High Voltage DC / DC Converter Command Pulse IJT #1-4 Control Circuit High-speed operation IJF Confirmation Pulse Engine ECU Injector

  49. Common-rail System • Diagnosis • DTCs for common-rail system Trouble Area Detection Condition Fail-safe

  50. Common-rail System • Diagnosis • DTCs for common-rail system Trouble Area Detection Condition Fail-safe 1 trip detection logic for all DTC

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