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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-112
1KD-FTV AND 2KD-FTV ENGINES
DESCRIPTION
1KD-FTV TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine) and 2KD-FTVTOYOTA D-4D are 3.0/2.5 liter, in-line 4-cylinder, 16-valve DOHC with turbocharged diesel engine.
These engines uses direct injection system and common-rail system to realize higher performance, cleanemission, low noise and low vibration.
A 2KD-FTV High Version, which has a higher power output than the normal 2KD-FTV engine, is alsoavailable. The 2KD-FTV and 2KD-FTV High Version engines are equipped with engine ECUscontaining engine control programs that differ from each other. However, both engine models share thesame mechanical components.
An intercooler is provided on all 1KD-FTV engine models and the 2KD-FTV High Version engine forThailand. This lowers the intake air temperature and improves power output.
The basic construction and operation of both the 1KD-FTV and 2KD-FTV engines are the same. Fordetails, see "Major Difference" on page EG-114.
1KD-FTV Engine
2KD-FTV Engine without Inter Cooler
271EG98
271EG97
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-113
Engine Specifications
Engine Type 1KD-FTV 2KD-FTV2KD-FTV
High Version
No. of Cyls. & Arrangement 4-Cylinder, In-line
Valve Mechanism16-Valve DOHC,Belt & Gear Drive
Combustion Chamber Direct Injection Type
Manifolds Cross-flow
Fuel System Common-Rail Type
Displacement cm3 (cu. in.) 2,982 (182.0) 2,494 (152.2)
Bore Stroke mm (in.)96.0 103.0
(3.78 4.06)
92.0 93.8
(3.62 3.69)
Compression Ratio 17.9 : 1 18.5 : 1
Max. Output [SAE-NET] 120 kW @ 3,400 rpm 75 kW @ 3,600 rpm 75 kW @ 3,600 rpm88 kW @ 3,600 rpm*5
Max. Torque [SAE-NET]343 Nm @
1,400 ~ 3,200 rpm200 Nm @
1,400 ~ 3,200 rpm
260 Nm @1,600 ~ 2,400 rpm
320 Nm @2,000 rpm*5
ValveTiming
IntakeOpen 2 BTDC
Close 37 ABDC 31 ABDC
ExhaustOpen 45 BBDC 30 BBDC
Close 0 ATDC
Firing Order 1-3-4-2
Fuel Cetan Number 50 or higher
Oil Grade CF-4, 10W-30
Emission Regulation
EURO III*2 EURO III*
5 EURO III*
8
EURO I*3 EURO I*
6 EURO I*
9
Tier 1*4 *7 *10
Engine Service Mass*(Reference) kg
(lb)
260 (573) 223 (492) 222 (489)
*1: Weight shows the figure with the oil and water fully filled.
*2: for Thai, Australian, and Central and South American Models
*3: for Philippine, and Central and South American Models (only for export package models)
*4: for Central and South American Models (only for Brazilian-spec models)
*5: for Thai Models
*6: for Philippine Models
*7: for General Countries Models
*8: for Thai, and Central and South American Models
*9: for Malaysian Models
*10: for General Countries, and Central and South American Models (only for export package models)
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-114
MAJOR DIFFERENCE
The table below lists the major differences between the 1KD-FTV and 2KD-FTV engines.
Section Item1KD
-FTV
2KD
-FTV
2KD
-FTV
High
Version
Engine Proper
A SIRM (Sintered Iron Reinforced Material) ring carrier isused in the top ring groove of the piston.
The piston skirt has been coated with resin.
An Ni-resist cast iron ring carrier is used in the top ringgroove of the piston.
A PVD (Physical Vapor Deposition) coating has beenapplied on the surface of the No. 1 compression ring
*1 *1
2 balance shafts are used.
Intake andExhaust System
A swirl control valve is used
A variable nozzle vane type turbocharger is used.
Air cooled type turbocharger is used.
An inter cooler is used. *2
An oxidation catalytic converter is used. *3 *3 *2
Fuel System Fuel cooler is used. *2
ChargingSystem
A segment conductor type alternator is used. *4 *
4
Starting System Planetary reduction type with interpolar magnet is used. *5 *
5
Engine Control
System
An EGR valve position sensor is used. *6 *6
An air flow meter is used.
Swirl control system is used.
Turbocharger control system is used.
*1: Only for emission regulation non-compliance models
*2: Only for Thai Models
*3: Only for EURO III or Tier 1 Compliance Models
*4: except Central and South American Models*
5: Only for Central and South American Models
*6: Only for Models with EGR System
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-115
FEATURES OF 1KD-FTV AND 2KD-FTV ENGINES
The 1KD-FTV and 2KD-FTV engines have achieved the following performance through the adoption ofthe items listed below.
(1) High performance and reliability(2) Low noise and vibration
(3) Lightweight and compact design(4) Good serviceability(5) Clean emission and fuel economy
Item (1) (2) (3) (4) (5)
EngineProper
A cylinder head cover made of plastic is used.
2 balance shaft is used.
Piston provided with combustion chamber is used in
conjunction with the adoption of direct injection.
The passage for the EGR is provided in the cylinder head.
Valve
MechanismA shim-less type valve lifter is used.
CoolingSystem
A pressurized reservoir tank is used.
Intake and
Exhaust
System
An intake shutter valve (throttle valve), which is actuated by
a torque motor (rotary solenoid type), and an airflow meterare used.
Swirl control valve is used.
A variable nozzle vane type turbocharger is used.
Air cooled type turbocharger is used.
An inter cooler is used.
Oxidation catalytic converter is used.
FuelSystem
HP3 type supply pump is used.
A common rail type fuel injection system is used.
Injector is provided in the bore center.
Compensation value and QR code printed injector is used.
Fuel cooler has been adopted.
A fuel filter, in which the fuel filter element alone can bereplaced, has been adopted.
A fuel filter warning switch that detects the clogging of thefuel filter has been adopted.
ChargingSystem
A segment conductor type alternator is used.
StartingSystem
Planetary reduction type with interpolar magnet is used.
Engine
ControlSystem
An EGR valve position sensor is used.
The no-contact sensor is used in the accelerator pedal
position sensor and intake shutter valve position sensor.
A pilot injection control system is used.
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-116
ENGINE PROPER 1. Cylinder Head Cover
The cylinder head cover is made of plastic toreduce weight and noise.
A baffle plate is provided on the inside of thecylinder head cover to reduce the consumptionof engine oil through blow-by gas.
2. Cylinder Head Gasket
A steel-laminate type cylinder head gasket has been adopted.
A shim has been added around the cylinder bore to increase the sealing surface, thus realizing excellentsealing performance
Service Tip
There are 5 sizes of new cylinder head gaskets,marked “A”, “B”, “C”, “D”, or “E” according to piston protrusion. For details, refer to Hilux
Repair Manual.
Baffle Plate
A-A Cross Section
271EG99
AA
271EG101
ABC
D
E
Rear
A
AFront
Shim
Cylinder
Bore SideA – A Cross Section
Outer
Side
271EG100
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-117
3. Cylinder Head
The cylinder head is made of aluminum alloy. The injector has been located in the center of thecombustion chamber in order to improve engine performance and clean emission.
Two intake ports with different shapes have been combined to promote the mixture of fuel and air byoptimizing the swirl in the cylinder.
A vertical two-stage construction is used for the water jacket to improve cooling performance.
A glow plug is placed between the intake ports of each cylinder to ensure startability.
The passage for the EGR is provided in the cylinder head. By cooling the exhaust gas, this makes it possible to re-circulate the great amount of exhaust gas.
The cylinder head bolt employs plastic region tightening bolts.
4. Cylinder Block
The cylinder block is constructed of liner-less cast iron alloy.
A rib has been added to the block of the cylinder block to reduce engine vibration.
Injector Hole
EGR Passage Glow Plug Hole
IN IN IN IN
EX EX EX EX
195EG42
Water Jacket
195EG41
Rib 271EG102
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-118
5. Balance Shaft (for 1KD-FTV Engine)
For in-line 4 cylinder engines, the main cause of vibration is imbalanced inertial force of reciprocating parts such as the pistons and connecting rods. The 1KD-FTV engine vibration has been reduced byusing 2 balance shafts to cancel the imbalanced inertial force, thereby reducing engine noise (boomingnoise).
These balance shafts are built into the cylinder block. Driven by the timing gear, the balance shaftsrotate at twice the speed of the crankshaft and in the opposite direction of each other.
6. Piston
In conjunction with the adoption of direct injection, piston provided with combustion chamber is used.
The piston is made of aluminum alloy.
A cooling channel has been provided to reduce the piston temperature.
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 castiron ring carrier.
On 1KD-FTV engine models and emission regulation non-compliance 2KD-FTV engine models, aPVD (Physical Vapor Deposition) coating has been applied to the surface of the No.1 compression ring,to improve its wear resistance.
The piston skirt portion of the 1KD-FTV engine has been coated with resin to reduce the friction loss.
Supply Pump
Drive Gear
Balance shaft No.1
Oil Pump
Drive Gear
Crankshaft
Timing Gear
Idle Gear
Balance Shaft No.2
195EG47
2KD-FTV Engine
Ni-resist Cast Iron
Ring Carrier
Cooling Channel 271EG159
1KD-FTV Engine
SIRM Ring Carrier
Cooling Channel271EG103
Resin
Coating
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-119
7. Connecting Rod and Connecting Rod Bearing
The connecting rods are made of high-strength material to ensure the proper strength.
Knock pins are used at the mating surfaces of the bearing caps of the connecting rod to minimize the
shifting of the bearing caps during assembly.
Plastic region tightening bolts are used.
An aluminum bearing is used for the connecting rod bearings.
8. Crankshaft and Crankshaft Bearing
The crankshaft has 5 journals and 8 balance weights. All pin and journal fillets are roll-finished to maintain adequate strength.
The crankshaft bearing is made of aluminum alloy.
The lining surface of the crankshaft bearing has been micro-grooved to realize an optimal amount of oil
clearance. As a result, cold-engine cranking performance has been improved and engine vibrations have been reduced.
The upper main bearing has an oil groove around its inside circumference.
271EG104
Plastic Region
Tightening Bolt
Knock Pin
Micro-Grooved
Roll-Finished
Upper Main Bearing
Lower Main Bearing
Oil Grooved
271EG105
Oil Hole
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-120
9. Crankshaft Pulley
The rigidity of the torsional damper rubber has
been optimized to reduce noise.Torsional Damper
Rubber
271EG106
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-121
VALVE MECHANISM 1. General
Each cylinder has 2 intake valves and 2 exhaust valves. Intake and exhaust efficiency is increased bymeans of the larger total port areas.
The valves are directly opened and closed by 2 camshafts.
The intake camshaft is driven by a timing belt, while the exhaust camshaft is driven through gear on theintake camshaft.
Small-diameter, and flat-teeth gears are used for driving the exhaust camshaft in order to reduce gear noise.
GearsExhaust Camshaft
Intake Camshaft
Timing Belt
271EG107
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-122
2. Camshaft
The cam nose has been chill treated to increase its abrasion resistance.
3. Intake and Exhaust Valves
Along with the increased amount of valve lift, shim-less valve lifters that provide a large cam contactsurface have been adopted.
The adjustment of the valve clearance is accomplished by selecting and replacing the appropriate valve
lifters.
: Chill Treated
Exhaust Camshaft
Intake Camshaft
Camshaft Drive Gear
Camshaft Drive Gear
224EG08
Camshaft
Valve
Lifter
208EG69
Service Tip
The valve lifters must be replaced when it is necessary to adjust the valve clearance. For this purpose, valve lifters with different thickness are available as service parts.
For details, refer to the Hilux Repair Manual.
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-123
4. Timing Gear Train
The supply pump, vacuum pump, oil pump and balance shafts* are driven by the crankshaft timinggear.
The idle gear is constructed with a scissors gear on its front and back to reduce noise.
*: Only for 1KD-FTV Engine
Camshaft Timing
Pulley No.1
Supply Pump
Drive Gear
Vacuum Pump
Drive Gear
Idle GearCrankshaft
Timing Gear
Oil Pump
Drive Gear
271EG161
Balance Shaft
Drive Gear*
Camshaft Timing
Pulley No.1
Automatic
Tensioner
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-124
LUBRICATION SYSTEM 1. General
The lubrication circuit is fully pressurized and all oil passes through an oil cooler and oil filter.
A trochoid oil pump driven by a gear engaged with the crankshaft is used.
A water-cooled type engine oil cooler is enclosed in the cylinder block.
Piston oil jets that lubricate and cool the piston are provided.
1KD-FTV Engine
271EG108
271EG109
Main Oil Hole
By-PassValve
By-PassValve
Relief
Valve
Oil
Filter
Oil
Cooler
OilPump
OilStrainer
Crankshaft
Journal No.1
Connecting
Rod
Gear
Oil Jet Vacuum
Pump
Idle
Gear
Oil Pan
Oil
Jet
Piston
CHECK
VALVE
Crankshaft
Journal No.2-5
Idle
Gear
Shaft
Turbo-
Charger
No.1Balance
Shaft
Journal
No.2
Balance
Shaft
Journal
DriveGearThrust
Washer
DriveGearThrust
Washer
Intake
Camshaft
Journal
Exhaust
Camshaft
Journal
Orifice
Cam
Gear
Valve
LifterValve
Lifter
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-125
2KD-FTV Engine
Oil Capacity
Engine Type 1KD-FTV 2KD-FTV
2KD-FTV High Version
Dry liters (US qts, Imp. qts.) 7.4 (7.8, 6.5)
With oil filter liters (US qts, Imp. qts.) 6.9 (7.3, 6.1)
Without oil filter liters (US qts, Imp. qts.) 6.6 (7.0, 5.8)
271EG111
Main Oil Hole
By-Pass
Valve
By-Pass
Valve
Relief
Valve
Oil Filter
Oil Cooler
Oil Pump
Oil
Crankshaft
Journal No.1
ConnectingRod
Gear
Oil Jet
Vacuum
Pump
Idle
Gear
Oil Pan
OilJet
Piston
Turbo-
Charger
Intake
CamshaftJournal
Exhaust
CamshaftJournal
Orifice
CHECK
VALVECrankshaft
Journal No.2-5
Idle
Gear
Shaft
Cam
Gear
Valve
LifterValve
Lifter
271EG110
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-126
2. Piston Oil Jet
Piston oil jets are provided at the bottom of the cylinder block to spray oil to the piston’s coolingchannel, thus further cooling and lubricating the piston.
These oil jets contain a check valve to prevent oil from being fed when the oil pressure is low. This prevents the overall oil pressure in the engine from dropping.
271EG112
Piston Oil Jet
Check
Valve
Oil
Cooling Channel
Back Side View
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-127
COOLING SYSTEM 1. General
The cooling system uses a pressurized forced circulation system with pressurized reservoir tank.
A pressurized reservoir tank has been adopted to prevent the engine coolant deteriorating upon contactwith external air.
A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperaturedistribution in the cooling system.
An aluminum radiator core is used for weight reduction.
A water-cooled type engine oil cooler is standard equipment.
A 3-stage temperature-controlled coupling fan, which uses the same bimetal that is used on theconventional model, controls the fan speed in three stages to improve cooling performance and reducecooling fan noise.
The TOYOTA genuine Super Long Life Coolant (SLLC) has been adopted. As a result, themaintenance interval has been extended.
Specifications
Transmission Type MT AT
Engine Coolant
TypeTOYOTA Genuine
Super Long Life Coolant (SLLC) or Equivalent
Capacity liters(US qts, Imp. qts)
9.8 (10.4, 8.6)*1 11.1 (11.7, 9.8)*
1
9.0 (9.5, 7.9)*2 10.3 (10.9, 9.1)*2
Thermostat Opening TemperatureC (F) 80-84 (176-183)
*1: Models with Heater*
2: Models without Heater
Reservoir Tank
Radiator
Thermostat
Oil Cooler
271EG113
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-128
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-129
System Diagram
Engine Coolant Specifications
Engine Coolant Type
TOYOTA Genuine
Super Long Life Coolant (SLLC)or Equivalent
TOYOTA Genuine
Long Life Coolant (LLC)or Equivalent
Color Pink Red
MaintenanceIntervals
First Time 160,000km (100,000miles)Every 40,000 km (24,000 miles) or24 months whichever comes firstSubsequent Every 80,000 km (50,000 miles)
SLLC is pre-mixed (50% coolant and 50% deionized water), so no dilution is needed when adding orreplacing SLLC in the vehicle.
If LLC is mixed with SLLC, the interval for LLC (every 40,000 km / 24,000 miles or 24 months) should
be used. You can also apply the new maintenance interval (every 80,000 km /50,000 miles) to vehicles initially
filled with LLC (red-colored), if you use SLLC (pink-colored) for the engine coolant change.
Radiator
Water Outlet
Turbocharger
Water
Pump
Cylinder Head
Oil Cooler
Heater
CoreThermostat
Water
Inlet
271EG114
Cylinder Block
Reservoir Tank
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-130
INTAKE AND EXHAUST SYSTEM 1. General
An intake shutter valve (throttle valve) equipped with a torque motor (rotary solenoid type) is used.
Swirl control valves are provided in the intake manifold of the 1KD-FTV engine.
A stainless steel exhaust pipe is used for weight reduction and improved rust resistance.
An air-cooled intercooler is provided on the 1KD-FTV engine and 2KD-FTV High Version engine forThailand.
An EGR system is provided on the models complying with the emission regulations (EURO III, EUROI, and Tier 1). This system is designed to reduce and control NOx formation through a slight reductionof peak temperature in the engine combustion chamber, which is accomplished by introducing a smallamount of inert gas into the intake manifold. For details on EGR control, see page EG-169.
A variable nozzle vane type turbocharger is used on the 1KD-FTV engine.
An air-cooled type turbocharger is used on the 2KD-FTV engine.
An oxidation catalytic converter is provided on the models complying with the EURO III or Tier 1emission regulation.
Intercooler
271EG115
Exhaust Manifold
Air Cleaner
Turbocharger
Intake Shutter Assembly
Intake Shutter Valve
(Throttle Valve) EGR Valve
Intake Manifold Oxidation Catalytic
Converter
Muffler
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-131
2. Intake Shutter Assembly
The intake shutter valve (throttle valve) equipped with the torque motor (rotary solenoid type) is used to
improve EGR performance and to reduce the vibration and noise when stopping the engine. The torquemotor (rotary solenoid type) makes the intake shutter valve (throttle valve) respond quickly.
3. Intake Manifold
In conjunction with the adoption of the direct injection system, an intake manifold provided with an airintake chamber is used in order to reduce the swirl variances between the cylinders.
On the 1KD-FTV engine, a vacuum-actuated swirl control valve is provided in one of the two intake
ports provided for each cylinder. A swirl control valve consists of a stainless steel shaft and an actuator,which are integrated in the valve. For details, see page EG-164.
Swirl Control Valve
Actuator
Air Intake Chamber
1KD-FTV Engine
271EG117
Intake Shutter Valve(Throttle Valve)
Torque Motor
(Rotary Solenoid type)
Intake Shutter ValvePosition Sensor
271EG116
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-132
4. Intercooler
An air-cooled intercooler is used in order to lower the intake air temperature, improve engine performance, and to realize cleaner exhaust gas emissions. It is located directly on top of the engine.
The intercooler and the inlet tank are made of aluminum and the outlet tank is made of plastic forweight reduction.
A dual construction, high-frequency cavity resonator is used for the pipe between the turbocharger andthe intercooler.
5. EGR Valve
An EGR valve is provided midstream in the intake air passage. By cooling the EGR valve in thismanner, a greater volume of exhaust gas can be processed.
On the 1KD-FTV engine, a vacuum port for a VSV (for EGR Valve Close) to cut off EGR is used to
improve valve closure response. On the 2KD-FTV engine, an EGR valve position sensor has been provided in the EGR valve in order to
directly measure the actual amount of the valve opening. This measurement is then input into theengine ECU in order to improve the precision of EGR control.
Front
Inlet Tank
Outlet Tank Hight-Frequency
Cavity Resonator
Intercooler
271EG118
271EG119
1KD-FTV Engine
to Intake
Manifold
Intake
Air
EGR Gas
Vacuum Port
EGR Valve
Position Sensor
2KD-FTV Engine
to Intake
Manifold
EGR Gas
Intake
Air
271EG120
Vacuum Port
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-133
6. Turbocharger
General
A variable nozzle vane type turbocharger is used for 1KD-FTV engine. A water jacket is provided inthe bearing housing to improve the cooling performance of the turbocharger.
A lightweight and compact air cooled type turbocharger is used for 2KD-FTV engine. To control the
turbo pressure, this turbocharger is provided with a wastegate valve and an actuator that operatesmechanically in accordance with the turbo pressure.
1KD-FTV Engine
2KD-FTV Engine without Intercooler
Water Jacket
Turbine
Wheel
Compressor
Wheel
DC MotorDC Motor
Nozzle Vane
Position Sensor
271EG121
Turbine WheelCompressor
Wheel
Wastegate Valve 271EG154
Only for 2KD-FTV Engine Models
The engine ECU determines altitude using the atmospheric pressure sensor. If the sensor indicationvalue is approx. 85kPa or less (Altitude: Higher than approx. 1,500 m), the engine ECU lowers the
preset maximum engine speed*, in order to prevent the turbine wheel from racing when the vehicle isdriven in high altitude areas (where the atmospheric pressure is low). Therefore, the preset maximum
engine speed is lower than standard. However, this is not an engine malfunction. For details, see theHilux Repair Manual.
*: Varies in accordance with altitude. As the altitude increases (the atmospheric pressure sensor
Service Tip
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-134
Variable Nozzle Vane type Turbocharger
Variable nozzle vane type turbocharger consists primarily of an impeller, turbine, nozzle vane, unisonring, DC motor and nozzle vane position sensor.
This turbocharger has realized great improvements in low-speed torque, maximum output, fuelconsumption, and emission reduction. These improvements have been accomplished through variablecontrol of the nozzle vane position, and an optimal velocity of the exhaust gas inflow to the turbine at
all times in response to the engine condition. The engine ECU outputs a signal to the turbo motor driver, which actuates the DC motor, to control
the nozzle vane position. For details on the turbocharger control, see page EG-165.
The exhaust gas from the exhaust manifold goes through the nozzle vane inside the turbo chargerhousing, and flows to the exhaust pipe through the turbine. The speed of the turbine (supercharging
pressure) differs depending on the flow velocity of the exhaust gas going through the turbine and theflow velocity of the exhaust gas is controlled by the opening. In such a time like idling, when theexhaust gas is less, the nozzle vane is almost fully closed, but as there is a slight clearance betweenthe vanes, the exhaust gas flows through this clearance to the exhaust pipe. Therefore, there is no bypass.
: Exhaust Gas
195EG72
: Intake Air
Nozzle Vane
DC Motor
Nozzle Vane
Position Sensor
Unison Ring
Linkage
Nozzle Vane
Turbine Wheel
271EG146
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-135
7. Exhaust Pipe
A stainless steel exhaust pipe is used for weight reduction and rust resistance.
A ball joint is used to join the exhaust front pipe and exhaust manifold. As a result, a simple and
reliable construction for reducing vibration has been realized.
The oxidation catalytic converter is used to clean the exhaust gas particulates, HC and CO. The table below describes the location of the converter (where equipped), in accordance with the engine type andexhaust emission regulation compliance.
Emission Regulation EURO III or Tier 1EURO I or
Non-Compliance
Engine Type
1KD-FTV
2KD-FTV High Version(with Intercooler)
2KD-FTV
2KD-FTV High Version(without Intercooler)
All
Location of OxidationCatalytic Converter
Integrated withFront Exhaust Pipe
BelowExhaust Manifold
Main Muffler
Oxidation Catalytic
Converter
Gasket
Main Muffler
Oxidation Catalytic
Converter
Gasket
271EG122
271EG151
1KD-FTV Engine and 2KD-FTV Engine with Intercooler
2KD-FTV Engine without Intercooler
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-136
FUEL SYSTEM
1. General
A common-rail system is used in the fuel injection system.
HP3 type supply pump, which is compact and lightweight, is used.
An injector compensation value and a QR code are printed on the injector to realize high-precisioncontrol.
A new type of fuel filter, in which the fuel filter element alone can be replaced, has been adopted.
A fuel filter warning switch, which turns ON/OFF when the internal vacuum of the filter increases, is provided in the fuel filter.
A fuel cooler made of aluminum has been adopted on the model equipped with an intercooler.
A fuel tank made of single-layer plastic has been adopted.
*: Only for Models with Intercooler
Fuel Tank
Injector
271EG123
Supply Pump
Common-Rail
Fuel Filter
Fuel Filter
Warning Switch Fuel Cooler*
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-137
2. Common-Rail System
General
In this system, the high pressurized fuel that is supplied by the supply pump is stored in the
common-rail, and the engine ECU sends signals to the injectors via the EDU (Electronic Driver Unit) inorder to control the injection timing and injection volume. For details of this control, see page EG-156.
System Diagram
*: Only for Models with Intercooler
Fuel Pressure Sensor Pressure Limiter
Common-Rail
SCVSupply
Pump
Fuel Temp. Sensor
Fuel Filter
Warning Light
Fuel
Filter
Fuel
Cooler* EDU
Engine ECU
NE Signal
G Signal
Pressure
Switch
Fuel Tank
271EG124
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-138
Supply Pump
1) General
This supply pump (HP3 type) has been made shorter than the HP2 type that is used on other models.This has been accomplished through the adoption of an opposing plunger configuration (and byreducing the number of plungers from 4 to 2), resulting in a compact and lightweight supply pump.
Specifications
Model New Hilux Other Model
Type HP3 (Outer Cam) HP2 (Inner Cam)
A Length mm (in.) 190.2 (7.49) 252.0 (9.92)
B Length mm (in.) 129.0 (5.08) 182.1 (7.17)
Suction Control Valve 1 2
Plunger φ8.5×2 φ7.0×4
Weight g (lb.) 3,800 (8.38) 6,040 (13.32)
224EG21
HP2
A
B
The engine ECU learns and memorizes the pump discharge volume variances associated with the
individual differences in the supply pumps. Therefore, make sure to perform the operation described below after replacing the supply pump. For details, see the Hilux Repair Manual.
Connect an intelligent tester II to the DLC3 connector and use the tester to reset the learned value.Alternatively, connect the SST (09843-18040) between the TC and CG terminals of the DLC3connector, and leave the ignition switch ON for approximately 3 minutes to reset the learned value.
After resetting, start the engine, allow it to idle* for approximately 1 minute, and turn the ignitionswitch OFF to enable the engine to memorize the learned value.
*: The engine coolant temperature should be 60C (140F) or more, and the fuel temperature
should be 20C 68F or more.
Service Tip
271EG155
HP3
A
B
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-139
2) Construction
The supply pump consists of an eccentric camshaft, ring cam, two plungers, four check valves, SCV(Suction Control Valve), fuel temperature sensor, and a feed pump.
The two plungers are placed opposite each other outside of the ring cam.
Plunger
Plunger
Ring Cam
Feed Pum
Eccentric
Camshaft
271EG157271EG158
Eccentric Cam
Portion
Eccentric Cam
Portion
Ring Cam
Check Valve
(for Suction) Check Valve
(for Discharge)
Check Valve
(for Suction)
SCV
Feed Pump
to Common-rail
Fuel Temp.
Sensor
Eccentric
Camshaft
Ring Cam
271EG156
Plunger
Check Valve
(for Suction)
Plunger
Check Valve
(for Suction)
from Fuel Tank
(for Suction)
to Fuel Tank
(for Return)Check Valve
(for Discharge)
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-140
3) Operation
Due to the rotation of the eccentric cam, the ring cam pushes plunger “A” upward as illustrated below. The force of the spring pulls plunger “B” (which is located opposite plunger “A”) upward. Asa result, plunger B draws fuel in, and plunger “A” pumps fuel at the same time.
The SCV controls the volume of fuel that is drawn into the plungers in accordance with the signalsfrom the engine ECU.
Engine
ECU
Engine
ECU
Engine
ECU
Engine
ECU
B Ring Cam
Eccentric
Cam
Check Valve
(for Discharge)Check Valve
(for Suction)
A
SCV
245EG08
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-141
Common-Rail
The function of the common-rail is to store the fuel that has been pressurized by the supply pump. Thecommon-rail is provided with a fuel pressure sensor, which detects the fuel pressure in thecommon-rail, and a pressure limiter that mechanically relieves the pressure in case the internal
pressure of the common-rail rises abnormally.
Internally, the common-rail contains a main hole and five branch holes that intersect the main hole.
Each branch hole functions as an orifice that dampens the fluctuation of the fuel pressure.
Fuel pressure sensor has its sealing portion plastic-deformed in order to keep sealing performance, so do not reuse it after disassembling.
If parts that affect the alignment have been changed, make sure to replace the pipe with a newone as well. The parts that require the replacement of a pipe are listed below.Injection Pipe: Injector, Common-rail, and Cylinder HeadFuel Inlet Pipe: Supply Pump, Common-rail, Cylinder Block, Water Pump, and Cylinder Head
For details, refer to the Hilux Repair Manual.
Service Tip
Fuel Pressure
Sensor
to Injectors
from Supply
Pump
Pressure Limiter
Branch Hole
Main Hole
Common-Rail Cross Section 271EG125
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-142
Injector
1) General
An injector consists of a nozzle needle, piston,and solenoid valve.
An injector compensation value and QR (Quick
Response) code containing encodedcharacteristics of the injector are printed oneach injector.
The injector compensation value and QR codecontain various pieces of information regarding
the injector, such as model code, and injectionvolume correction.
If the engine ECU is replace, use the intelligent tester II and input the injector compensationvalues of all 4 injectors. If the injector is replaced, input the injector compensation value of thereplaced injector. Then, the proper compensation will be made so that the injection volume
precision prior to the replacement will remain unchanged. For details, see the Hilux RepairManual.
The QR code, which requires a special scan tool, is not used at Toyota dealers.
Service Tip
- REFERENCE -
What is QR (Quick Response) Code?
QR code, a matrix symbology consisting of an array of nominally square cells, allowsomni-directional, high-speed reading of large amounts of data.
QR code encodes many types of date such as numeric, alphanumeric, kanji, kana and binarycode. A maximum of 7,089 characters (numeric) can be encoded.
QR code (2D code) contains information in the vertical and horizontal direction, whereas a bar
code contains date in one direction only. QR code (2D code) holds a considerably greatervolume of information than a bar code.
271EG152
Nozzle Needle
Piston
Solenoid Valve
QR Code
Injector CompensationValue
271EG153
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-143
2) Operation
(a) When electrical current is applied to the solenoid coil, it pulls the solenoid valve up.(b) The orifice of the control chamber opens, allowing the fuel to flow out.(c) The fuel pressure in the control chamber drops.(d) Simultaneously, fuel flows from the orifice to the bottom of the piston and raises the piston up (to
enhance response).
(e) As a result, the piston raises the nozzle needle to inject fuel.
271EG127
Fuel
Solenoid Coil (a)
Solenoid Valve
Piston ControlChamber
Nozzle
Needle
Fuel
(b)
(c)
(d)
(e)
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-144
3. Fuel Filter
General
The conventional fuel filter consists of a fuel filter element integrated with the fuel filter housing. Bycontrast, the new fuel filter consists of a separate fuel filter housing and a fuel filter element.
A paper filter element that offers high filtering efficiency and captures the minutest particles has been
adopted.
Fuel Filter Warning Switch
A fuel filter warning switch, which turns ON/OFF when the internal vacuum of the filter increases, is provided in the fuel filter. This switch, which turns OFF when the internal vacuum of the fuel filterincreases to a predetermined level, is connected by wire to the meter ECU.
When the meter ECU detects that the internal vacuum of the fuel filter has increased (by way of thefuel filter warning switch OFF signal), it determines that the fuel filter has become clogged. Then, itilluminates the fuel filter warning light on the combination meter to urge the driver to replace the fuelfilter. For details on fuel filter warning light control, see page BE-XX.
271EG129
Fuel Filter
Warning LightMeter ECU
Combination Meter
Fuel Filter
Warning Switch
Diaphragm
from
Fuel Tank
to Supply Pump
FilterElement
Fuel Filter
Meter ECU
Combination Meter
Normal Fuel Filter Fuel Filter Clogged Up
Negative Pressure
Vacuum
Fuel Filter
Fuel FilterWarning Switch
FilterElement
FilterHousing
Fuel SedimenterLevel Warning
New Conventional
Fuel Sedimenter
Level Warning
Fuel Filter Assembly
Filter Element
Priming Pump
Priming
Pump
271EG128
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-145
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-146
4. Fuel Cooler
The fuel cooler, which is provided in the fuel return path, cools the return fuel that has reached a high
temperature as a result of the pumping of the supply pump. This prevents the reduction in fuel viscositythat is caused by the rise in fuel temperature, and improves the reliability of the fuel system.
A
A A-A Cross Sectionto
Fuel Tankfrom
Common-Rail271EG130
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-147
CHARGING SYSTEM
As on the 2TR-FE engine model, a compact andlightweight segment conductor type alternator(SE08 type) that generates a high amperageoutput in a highly efficient manner has been
adopted as standard equipment on models exceptthe Central and South American models. Fordetails on this alternator, see page EG-28.
The Central and South American models haveadopted the conventional (KCB1 type) alternatormade by Bosch.
A one-way clutch function has been provided inthe pulley of 2 type alternators to absorb thefluctuations in the engine speed, thussignificantly reducing the damage sustained by
the drive belt.
STARTING SYSTEM
As on the Central and South American 2TR-FE engine models, a planetary reduction type starter with aninterpolar magnet (DW2.2 type) has been adopted on the Central and South American models (exceptKUN26L-PRPSYG). For details on the interpolar magnet, see page EG-32.
The models except those indicated above use a conventional reduction type starter (RA2.0, R2.2, or R2.7type).
SST (09820-63020) has been established due to the adoption of a pulley with the one-way clutch
function. For details, refer to the Hilux Repair Manual.
Service Tip
One-way Clutch
271EG165
Alternator Pulley
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ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-148
SERPENTINE BELT DRIVE SYSTEM
Accessory components are driven by a serpentine belt consisting of a single V-ribbed belt. It reduces the overall engine length, weight and number of engine parts.
An automatic tensioner eliminates the need for tension adjustment.
Air Conditioner
Compressor Pulley*
Idler Pulley
Alternator Pulley
Automatic Tensioner
Crankshaft Pulley
Water Pump Pulley
Idler Pulley
210EG34
*: Only for Models with Air Conditioner