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Model Outline KD Series Engine Chassis Body Body Electrical Contents Click a Section Tab

Toyota Hilux

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Page 1: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ContentsClick a Section Tab

Page 2: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine OverallEngine ProperValve MechanismLubrication System Intake and Exhaust SystemCommon-rail SystemFuel SystemCharging SystemSerpentine Belt Drive SystemEngine Control System

Page 3: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine Overall1KD-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

Page 4: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine Overall1KD-FTV / 2KD-FTV Specifications

Item1KD-FTV(HILUX,

FORTUNER)

2KD-FTV(HILUX, FORTUNER,

INNOVA)

No. of Cylinders & Arrangement 4-Cylinder, In-line

Valve Mechanism16-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 Strokemm (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. OutputkW @ rpm

120 @ 3,40075 @ 3,600

88 @ 3,600 *2

Max. TorqueN·m @ rpm

343 @1,400 ~ 3,200

200 @ 1,400 ~ 3,200260 @ 1,600 ~ 2,400 *1

320 @ 2,000 *2

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

Page 5: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine OverallFeatures– 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

Page 6: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine OverallFeatures– Under floor Fuel Cooler

(with intercooler model only)

Front

Page 7: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine ProperPiston– In conjunction with the adoption of direct injection,

combustion chamber is provided on piston

Combustion Chamber

Ni-resist Cast Iron

Ring Carrier

Cooling Channel

1KD-FTV 2KD-FTV

SIRM Ring

Carrier

Page 8: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Valve MechanismTiming 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

Page 9: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Lubrication SystemLubrication System– Overall

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

Oil Cooler

Oil Filter

Page 10: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemIntake Shutter Valve– Rotary solenoid type intake shutter valve is used to

improve EGR performanceEngine

ConditionValve

PositionPurpose

StartingFull

OpenReduced Diesel Smoke

RunningSmall -

Full Open

Controls EGR amount

StopFull

CloseReduced noise and vibration

Rotary Solenoid type Motor

Intake Shutter Valve Position Sensor

Intake Shutter Valve

Air flow

Page 11: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemIntake Shutter Valve– Construction

Hall ICHall IC

MagnetMagnet

MagnetMagnetSteel LayerSteel Layer

MagnetMagnet

Intake Shutter Valve Position Sensor

Intake Shutter Valve Position Sensor

Rotary Solenoid Type Motor

Rotary Solenoid Type Motor

Page 12: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemIntake Manifold– Two intake port with different shape from intake

manifold to cylinder head• For swirl optimizing in cylinder

Page 13: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemSwirl 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

Page 14: Toyota Hilux

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 SystemSwirl Control Valve (1KD only)– Operation

Actuator

Intake Air

VSV

Vacuum Pump

Engine ECU

Accelerator Pedal Opening

Engine Speed

ON / OFF

Page 15: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemVariable 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

Page 16: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemVariable 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

Page 17: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemVariable 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

Page 18: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Feedback Control

Nozzle Vane

Position

Turbo Motor Driver

Target Angle

Control StatusEngineECU

Turbo Pressure Sensor

Atmospheric Temp. Sensor

Atmospheric Pressure Sensor

Water Temp. Sensor

Injector (EDU)

Crankshaft Position Sensor

DC Motor

Nozzle Vane

Position Sensor

Control

Page 19: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemVariable 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

0Link

0

Link is bumped to full-close

stopper

Link is bumped to full-close

stopper

Zero point calibrationZero point calibration

Nozzle vane is controlled based on the zero point

Nozzle vane is controlled based on the zero point

Page 20: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemVariable Nozzle Vane Type Turbocharger (1KD only)– Operation movie

Click!Movie

Page 21: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemTurbocharger (2KD only)– Light weight, compact and high performance

turbocharger

Waste Gate Valve

Actuator for Waste

Gate Valve

Page 22: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemIntercooler– Intake air is cooled in intercooler to increase the air

density

Turbocharger

Thermal Expansion Contraction Increase

oxygen densityOxygen

Page 23: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Intake and Exhaust SystemIntercooler– Intake air is cooled in intercooler to increase the air

density

Page 24: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemGeneral

Fuel Pressure Sensor

EDU

Pressure Limiter

Supply PumpSCV

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

Page 25: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFeatures

Fuel Pressure Sensor

EDU

Pressure Limiter

Supply PumpSCV

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

typeDetects

filter clogging

Detects filter

clogging

Fuel cooler cools return

fuel

Fuel cooler cools return

fuel

Page 26: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemGeneral– 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

SCVSupply 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)

Page 27: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSystem 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

TimerGovernor

PumpInjection Nozzle

Page 28: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemLocation

Common-rail•Fuel Pressure Sensor

•Pressure LimiterSupply Pump•SCV (Suction Control Valve)

•Fuel Temp. Sensor

Injector

Engine Front

Injection Pipe

Fuel Inlet Pipe

Page 29: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply 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)

Page 30: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Construction

Plunger Feed Pump

Delivery Valve

SCV (Suction Control Valve)

Fuel Temp. Sensor

Check Valve

Eccentric and Ring Cam

Page 31: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Construction

Ring Cam

Plunger

Eccentric Cam

To fuel tank (return)

Page 32: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Fuel flow

From fuel tank

To common-rail

Page 33: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Fuel flow (reference)

Click!Movie

Page 34: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Suction and pumping operation

SCV

: From Feed Pump : To Common-rail

Plunger A: SuctionPlunger B: Pumping

Plunger A: PumpingPlunger B: Suction

Plunger A

Plunger B

Check Valve

Page 35: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Suction and pumping operation

Click!Movie

Page 36: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Fuel control operation (SCV opening small)

Fuel Pumping

Mass

Page 37: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Fuel control operation (SCV opening large)

Fuel Pumping

Mass

Page 38: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Fuel control operation (SCV opening small)

Click!Movie

Page 39: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply Pump– Fuel control operation (SCV opening large)

Click!Movie

Page 40: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemSupply 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]

Page 41: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemCommon-rail– Stores high-pressure fuel (Max. 160 MPa) produced by

supply pump

FromSupply Pump To Injector To Fuel Tank

Fuel Pressure Sensor

Pressure Limiter

Common-rail

Page 42: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemCommon-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)

Outp

ut

Volt

age (

V)

Output characteristic Sensor Tip

90

2.44

Page 43: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemInjector– High pressure injection for higher atomization

Injector Compensation

CodeFromCommon-rail

Return toFuel Tank

0.14 mm

Page 44: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemInjector– Construction

Nozzle Needle

Piston

Solenoid Coil

Return toFuel Tank

FromCommon-rail

Nozzle Spring

Page 45: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemInjector– Controlled by engine ECU signal

SolenoidSolenoid

TWV

Return

From Common-rail Large

Orifice

Small Orifice

Click!Movie

Page 46: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemInjector– Pilot injection reduces NOx and engine noise

TDCTDC

PilotInjection Control

Conventional Injection Control

PilotMain

Heat Release Value

Injection Volume

NOx and engine noise

Page 47: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemInjector– Pilot injection reduces NOx and engine noise

Page 48: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemEDU (Electronic Driver Unit)– Drive the injectors at high speed

Engine ECU

EDU

Injector

High VoltageDC / DC

ConverterDC / DC

Converter

Command Pulse

Confirmation Pulse

Battery

IJT #1-4

IJF

Control CircuitControl Circuit High-speed

operation

Page 49: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fail-safeDetection Condition

Common-rail SystemDiagnosis– 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

Page 50: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemDiagnosis– 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

Page 51: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemDiagnosis– DTCs for common-rail system

DTC No. Detection Item Fail-safe

P0087 (49)

Fuel Rail/System Pressure - Too Low

Limits engine powerP0088 (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 powerP0192(49)

Fuel Rail Pressure Sensor Circuit Low Input

P0193(49)

Fuel Rail Pressure Sensor Circuit High Input

Trouble Area Fail-safeDetection Condition

Page 52: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemDiagnosis– 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

Page 53: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemDiagnosis– 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

Page 54: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemDiagnosis– 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

Page 55: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Common-rail SystemService 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

Page 56: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFuel Filter– Replace fuel filter element only

Fuel Filter Warning Switch

From Fuel TankTo Supply Pump

Priming Pump

Filter Housing (Plastic)

Fastener Nut

Drain Cock

Filter Element

Page 57: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFuel 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

Page 58: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFuel 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

Clogging

Page 59: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFuel 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

Page 60: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFuel 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

Page 61: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

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

WarningWarning Method

Priority

Sedimenter Warning

Blink

1

Fuel Filter Warning

ON

2

Page 62: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Fuel SystemFuel 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

Page 63: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Charging SystemAlternator Pulley

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

RollerSpring

Page 64: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Charging SystemAlternator Pulley– Engine fluctuation absorbing mechanism

EngineFluctuation

Alternator Pulley Speed

Crankshaft Pulley Speed

Pulle

y S

peed (

rpm

)

Time

One-wayClutch

Locked

One-wayClutchFree

Page 65: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Serpentine Belt Drive SystemSerpentine 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

Page 66: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine Control SystemOil Maintenance Management System– This system determines the deterioration conditions of

the engine oil

Page 67: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine Control SystemOil Maintenance Management System– System diagram and general operation

Soot Volume ODO / TRIP

Switch

Engine ECUEngine 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

Page 68: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine Control SystemOil Maintenance Management System– Soot calculating logic

A/F Ratio

Injection End Timing

SootVolume

Rich

Lean

Retard

Advance

Page 69: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Engine Control SystemOil Maintenance Management System– Engine oil change reminder light operation

ConditionEngine Oil Change

Reminder Light

Mileage = 35,000 km ~ 40,000 kmor

Specified Soot Volume A

Mileage = 40,000 km or more or

Specified Soot Volume B

Page 70: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

Page 71: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ReferenceIntake Shutter Valve– Intake shutter valve position sensor

Intake Shutter Valve Opening Angle (°)

Ou

tput

Volt

age (

V)

0

Engine ECU

VC

VLU

Hall IC

Magnet

E20

(Full Close)70

(Full Open)

Intake Shutter Valve Position

Sensor

Intake Shutter Valve Position

Sensor

1

5

0.71

20 100

3.51

Page 72: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ReferenceVariable 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 ()

Outp

ut

Volt

age (

V)

Output characteristic of main, sub sensor

VN Close

VN Open

-55 55

Hall ICs

Magnets

Cross-section

0

Page 73: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ReferenceFuel 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

Page 74: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ReferenceFuel Cooler– Construction

FromSupply Pump / Injector

To Fuel Tank

Cross Section

Fin

Page 75: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ReferenceAccelerator Pedal– Non-contact type accelerator pedal position sensor is

used

Accelerator Pedal Position Sensor

Page 76: Toyota Hilux

Model Outline KD Series Engine Chassis Body Body Electrical

ReferenceAccelerator Pedal– Using magnet and hall IC

Accelerator Pedal Depressed Angle

Full OpenFull Close

VPA1

VPA2

Ou

tput

Volt

age (

V)

0

5

VCP1

VCP2

VPA2

VPA1

Hall IC

Magnets

EP1

EP2

Engine ECU

Accelerator Pedal Position

Sensor