Model Outline
Contents
KD Series Engine
Click a Section Tab
Chassis
Body
Body Electrical
Model Outline
KD Series Engine
Chassis
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
Body
Body Electrical
Model Outline
KD Series Engine
Engine Overall
Chassis
Body
Body Electrical
1KD-FTV / 2KD-FTV
– TOYOTA D-4D, 3.0 / 2.5 liter, in-line 4-cylinder,
16 valve DOHC with turbocharged diesel engine
1KD-FTV
2KD-FTV
Model Outline
Chassis
KD Series Engine
Engine Overall
Body
Body Electrical
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

Common-Rail Type

With
Without / With *2
cm3 (cu. in.)
2,982 (182.0)
2,492 (152.2)
mm (in.)
96.0 x 103.0
(3.78 x 4.06)
92.0 x 93.8
(3.62 x 3.69)
18.4
18.5
120 @ 3,400
75 @ 3,600
88 @ 3,600 *2
343 @1,400 ~
3,200
200 @ 1,400 ~ 3,200
260 @ 1,600 ~ 2,400 *1
320 @ 2,000 *2
Fuel System
Intercooler
Displacement
Bore x Stroke
Compression Ratio
Max. Output
Max. Torque
kW @ rpm
N·m @ rpm
*1: 2KD-FTV High Version
*2: 2KD-FTV High Version (HILUX for Thai only)
Model Outline
KD Series Engine
Engine Overall
Chassis
Body
Body Electrical
Features
– Engine compartment
Rotary Solenoid Type
Diesel Throttle
VN Type Turbocharger
(1KD only)
Photo: 1KD-FTV
SLLC
Fuel Filter
•Fuel filter warning (clogging detection)
•Element replacing type
Model Outline
KD Series Engine
Engine Overall
Features
– Under floor
Front
Chassis
Body
Body Electrical
Fuel Cooler
(with intercooler model only)
Model Outline
KD Series Engine
Engine Proper
Chassis
Body
Body Electrical
Piston
– In conjunction with the adoption of direct injection,
combustion chamber is provided on piston
Combustion
Chamber
SIRM
Ring
Carrier
Ni-resist
Cast Iron
Ring Carrier
Cooling
Channel
1KD-FTV
2KD-FTV
Model Outline
KD Series Engine
Valve Mechanism
Chassis
Body
Body Electrical
Timing Belt
– Maintenance interval: replace at every 150,000 km
Camshaft
Timing
Pulley No. 2
Oil Pump Drive Gear
Crankshaft Timing Gear
Supply Pump Drive Gear
Timing
Belt
Automatic
Belt
Tensioner
Camshaft
Timing
Pulley No. 1
Vacuum Pump Drive Gear
Idle Gear
Model Outline
KD Series Engine
Lubrication System
Chassis
Body
Body Electrical
Lubrication System
– Overall
• Lubrication is fully pressurized and all oil passes
through an oil cooler and oil filter
Oil Filter
Oil Cooler
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
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
Stop
Full
Close
Controls EGR
amount
Reduced noise
and vibration
Air flow
Intake Shutter Valve
Rotary Solenoid type Motor
Intake Shutter Valve
Position Sensor
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Intake Shutter Valve
– Construction
Intake Shutter Valve
Position Sensor
Rotary Solenoid
Type Motor
Steel Layer
Magnet
Hall IC
Magnet
Magnet
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Intake Manifold
– Two intake port with different shape from intake
manifold to cylinder head
• For swirl optimizing in cylinder
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
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
Model Outline
KD Series Engine
Chassis
Body
Intake and Exhaust System
Body Electrical
Swirl Control Valve (1KD only)
– Operation
Intake
Air
At low engine speed,
SCV is closed to
strengthen the swirl
Actuator
Vacuum
Pump
VSV
Engine Speed
ON / OFF
Engine
ECU
Accelerator
Pedal Opening
Model Outline
Chassis
KD Series Engine
Body
Intake and Exhaust System
Body Electrical
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
FullClose
Stopper
Model Outline
Chassis
KD Series Engine
Body
Intake and Exhaust System
Body Electrical
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
Nozzle Vane
FullClose
Stopper
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
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
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Variable Nozzle Vane Type Turbocharger (1KD only)
– Feedback Control
Injector (EDU)
Crankshaft
Position Sensor
Turbo Pressure
Sensor
Atmospheric
Temp. Sensor
Water Temp.
Sensor
Target Angle
Engine
ECU
Atmospheric
Pressure
Sensor
Control Status
Turbo Motor
Driver
Control
Nozzle
Vane
Position
DC
Motor
Nozzle
Vane
Position
Sensor
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Variable Nozzle Vane Type Turbocharger (1KD only)
– Zero point calibration
IG
ON  OFF
Link is bumped
to full-close
stopper
IG
Zero point
calibration
OFF  ON
Motor Rod
Open
0
Close
After the
engine
start
Nozzle vane is
controlled based
on the zero point
0
Link
Full-Close
Stopper
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Variable Nozzle Vane Type Turbocharger (1KD only)
– Operation movie
Click!
Movie
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Turbocharger (2KD only)
– Light weight, compact and high performance
turbocharger
Waste Gate
Valve
Actuator
for Waste
Gate Valve
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Intercooler
– Intake air is cooled in intercooler to increase the air
density
Thermal
Expansion
Oxygen
Turbocharger
Increase
oxygen density
Contraction
Model Outline
KD Series Engine
Chassis
Intake and Exhaust System
Body
Body Electrical
Intercooler
– Intake air is cooled in intercooler to increase the air
density
Model Outline
Chassis
KD Series Engine
Fuel System
Body
Body Electrical
General
NE Signal
Engine
ECU
G Signal
EDU
Other Injectors
Various
Signals
Fuel Pressure
Sensor
Pressure
Limiter
Common-rail
Injector
Pressure
Switch
Fuel Cooler
SCV
Supply Pump
Fuel System
Warning Light
Fuel
Filter
Fuel Tank
Model Outline
Chassis
KD Series Engine
Fuel System
Body
Body Electrical
Features
NE Signal
Engine
ECU
G Signal
EDU
Injector
compensation
code
Other Injectors
Various
Signals
Max. 160MPa
HP3 Type
Fuel Pressure
Supply
Sensor
Pump
Pressure
Limiter
Common-rail
Injector
Pressure
Switch
Fuel Cooler
Warning
Supplylight
Pump
for fuel filter
clogging and
fuel sedimenter
SCV
Fuel
Filter
Fuel System
Warning
Light
Detects
filter
clogging
Element
replacement
type
Fuel Tank
Fuel cooler
cools return
fuel
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
General
– This system realize high injection pressure in all speed
range of the engine
NE Signal
G Signal
EDU
(Operates injector
at high-speed)
Engine
ECU
Various
Signals
Fuel Pressure
Sensor
Pressure
Limiter
Common-rail
(Stores high-pressure fuel)
Injector
(Injects high-pressure fuel)
SCV
Supply Pump
(Generates high-pressure fuel)
Fuel Tank
: High-pressure (Max. 160 MPa)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
System Outline
Common-rail Diesel
Constant high pressure
Pressure
Common-rail
Sensor
System
SCV
Conventional Diesel
Instantaneously high pressure
Governor
Timer
ECU
Supply Pump
Injector
Pump
Injection
Nozzle
Injection Volume
Control
ECU (Injector)
Pump (Governor)
Injection Timing
Control
ECU (Injector)
Pump (Timer)
Injection Pressure
Control
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Location
Engine
Front
Injection Pipe
Injector
Fuel Inlet Pipe
Common-rail
Supply Pump
•SCV (Suction Control Valve)
•Fuel Temp. Sensor
•Fuel Pressure Sensor
•Pressure Limiter
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Supplies the high pressure fuel to the common-rail
– Driven by crankshaft
To Common-rail
(Outlet)
To Fuel Tank
(Return)
SCV
(Suction Control Valve)
From Fuel Filter
(Inlet)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Construction
Check
Valve
Eccentric and
Ring Cam
Plunger
Delivery
Valve
Feed
Pump
Fuel
Temp.
Sensor
SCV (Suction
Control Valve)
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Construction
To fuel tank
(return)
Ring Cam
Plunger
Eccentric
Cam
Model Outline
KD Series Engine
Common-rail System
Supply Pump
– Fuel flow
Chassis
To common-rail
From fuel
tank
Body
Body Electrical
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Supply Pump
– Fuel flow (reference)
Click!
Movie
Body Electrical
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Suction and pumping operation
Plunger A: Suction
Plunger B: Pumping
Plunger A: Pumping
Plunger B: Suction
Check
Valve
Plunger A
SCV
Plunger B
: From Feed Pump
: To Common-rail
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Suction and pumping operation
Click!
Movie
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Fuel control operation (SCV opening small)
Fuel
Pumping
Mass
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Fuel control operation (SCV opening large)
Fuel
Pumping
Mass
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Fuel control operation (SCV opening small)
Click!
Movie
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– Fuel control operation (SCV opening large)
Click!
Movie
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Supply Pump
– The SCV opening regulates the pumping volume to
control fuel pressure
[Fuel Pressure Control]
Fuel Pressure
Sensor
SCV
Controls
SCV
opening
Common-rail
pressure
(Feedback)
Calculation of
target injection
pressure
Engine ECU
Crankshaft
Position Sensor
Accelerator Pedal
Position Sensor
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Common-rail
– Stores high-pressure fuel (Max. 160 MPa) produced by
supply pump
Pressure
Limiter
Fuel
Pressure
Sensor
Common-rail
From
Supply Pump
To Injector
To Fuel Tank
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Common-rail
– Fuel pressure sensor
• Detects the internal fuel pressure of common-rail
Output characteristic
Output Voltage (V)
Sensor Tip
4.04
2.44
1.0
0
90
190
Common-rail Pressure (MPa)
Common-rail
Pressure
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Injector
– High pressure injection for higher atomization
Return to
Fuel Tank
From
Common-rail
Injector
Compensation
Code
0.14 mm
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Injector
– Construction
Solenoid Coil
Return to
Fuel Tank
From
Common-rail
Piston
Nozzle
Spring
Nozzle
Needle
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Injector
– Controlled by engine ECU signal
Solenoid
Solenoid
TWV
Small
Orifice
From
Common-rail
Click!
Movie
Return
Large
Orifice
Body Electrical
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Injector
– Pilot injection reduces NOx and engine noise
Main
Injection
Volume
Pilot
NOx and
engine noise
Heat
Release
Value
TDC
Pilot
Injection Control
TDC
Conventional
Injection Control
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Injector
– Pilot injection reduces NOx and engine noise
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
EDU (Electronic Driver Unit)
– Drive the injectors at high speed
EDU
Battery
DC / DC
Converter
Command
Pulse
IJT
#1-4
IJF
Engine
ECU
Confirmation
Pulse
Control
Circuit
High
Voltage
High-speed
operation
Injector
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
– DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Trouble Area
P0087
(49)
Fuel Rail/System
Pressure - Too Low
•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
P0192
(49)
Fuel Rail Pressure Sensor
Circuit Low Input
P0193
(49)
Fuel Rail Pressure Sensor
Circuit High Input
• Open or short in fuel pressure sensor
circuit
•Fuel pressure sensor
•Engine ECU
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
– DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Detection Condition
P0087
(49)
Fuel Rail/System
Pressure - Too Low
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 Fuel pressure sensor output voltage is
Circuit Malfunction
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
– DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
P0087
(49)
Fuel Rail/System
Pressure - Too Low
P0088
(78)
Fuel Rail/System
Pressure - Too High
P0093
(78)
Fuel System Leak
Detected - Large Leak
P0190
(49)
Fuel Rail Pressure Sensor
Circuit Malfunction
P0192
(49)
Fuel Rail Pressure Sensor
Circuit Low Input
P0193
(49)
Fuel Rail Pressure Sensor
Circuit High Input
Detection Condition
Fail-safe
Fail-safe
Limits engine power
Limits engine power for 1 min., and then
stops the engine
Limits engine power
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
– DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Trouble Area
P0200
(97)
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
– DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
Detection Condition
Fail-safe
Detection Condition
P0200
(97)
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
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
Diagnosis
– DTCs for common-rail system
Trouble Area
DTC No.
Detection Item
P0200
(97)
Injector Circuit / Open
P0627
(78)
Fuel Pump Control Circuit
/ Open
P1229
(78)
Fuel Pump System
P1601
(89)
Injector Correction
Circuit Malfunction
(EEPROM)
Detection Condition
Fail-safe
Limits engine power
-
Fail-safe
Model Outline
KD Series Engine
Common-rail System
Chassis
Body
Body Electrical
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
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Filter
– Replace fuel filter element only
Priming
Pump
From Fuel Tank
Fuel Filter
Warning Switch
To Supply Pump
Fastener Nut
Filter Housing
(Plastic)
Filter Element
Drain Cock
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Filter
– Construction
Priming
Pump
From Fuel Tank
Fuel Filter
Warning Switch
To Supply Pump
Fastener Nut
Filter Element
Filter Housing
(Plastic)
Fuel Sedimenter Level
Warning Switch
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Warning System
– Fuel filter clogging is detected by fuel filter warning
switch
Fuel Filter
Warning Switch
Fuel System
Warning Light
Clogging
Combination Meter
Fuel Filter
- Fuel Filter Maintenance Interval Fuel system warning light has been illuminated
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Warning System
– System Diagram
Combination Meter
Vehicle Speed
Sensor
Fuel Filter
Warning Switch
Meter
ECU
Fuel System
Warning Light
To Supply Pump
Filter Element
Fuel Filter
Fuel Sedimenter Level Warning Switch
Model Outline
Chassis
KD Series Engine
Fuel System
Body
Body Electrical
Fuel Warning System
– Fuel filter warning switch turns OFF when the filter
outlet pressure decreases
Fuel Filter
Warning
Switch
ON Meter
ECU
Fuel Filter
Warning
Switch
OFF Meter
ECU
Diaphragm
To Supply Pump
Filter Element
Normal Fuel Filter
(Switch: ON)
To Supply Pump
Negative
Pressure
Fuel Filter Clogged Up
(Switch: OFF)
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Warning System
– Warning light condition for fuel filter / fuel sedimenter
Warning
Warning
Method
Sedimenter
Warning
Priority
1
Blink
Fuel Filter
Warning
2
ON
Model Outline
KD Series Engine
Fuel System
Chassis
Body
Body Electrical
Fuel Warning System
– Detection conditions
After the driving for 30 min. or more
Fuel Filter Warning Switch Condition
OFF for 10 min.
or more
or
OFF is detected for 2
times during 1 trip
The warning light keeps ON until the reset operation is done
Model Outline
KD Series Engine
Charging System
Chassis
Body
Body Electrical
Alternator Pulley
• In order to absorb a engine fluctuation, one-way
clutch was adopted in the pulley
Spring
Roller
Model Outline
KD Series Engine
Charging System
Chassis
Body
Body Electrical
Alternator Pulley
– Engine fluctuation absorbing mechanism
One-way
Clutch
Locked
Crankshaft Pulley
Speed
One-way
Clutch
Free
Pulley Speed (rpm)
Alternator
Pulley Speed
Engine
Fluctuation
Time
Model Outline
KD Series Engine
Chassis
Serpentine Belt Drive System
Body
Body Electrical
Serpentine Belt Drive
– Single V-ribbed belt
Air Conditioner
Compressor Pulley
Idler Pulley
Idler Pulley
Water Pump
Pulley
Alternator Pulley
with Shock
Absorbing Function
Idler Pulley for
Automatic Tensioner
Crankshaft Pulley
Model Outline
KD Series Engine
Engine Control System
Chassis
Body
Body Electrical
Oil Maintenance Management System
– This system determines the deterioration conditions of
the engine oil
Model Outline
KD Series Engine
Engine Control System
Chassis
Body
Body Electrical
Oil Maintenance Management System
– System diagram and general operation
Engine Oil Change
Reminder Light
Engine ECU
Blink or ON
•Engine Speed
•Injection Volume
•Injection Timing
•A/F Ratio
Meter ECU
Soot
Volume
ODO / TRIP
Switch
Soot Volume
Calculation
Vehicle
Speed
Model Outline
KD Series Engine
Engine Control System
Chassis
Body
Body Electrical
Oil Maintenance Management System
– Soot calculating logic
Soot
Volume
Retard
Injection
End Timing
Rich
A/F Ratio
Lean
Advance
Model Outline
KD Series Engine
Engine Control System
Chassis
Body
Body Electrical
Oil Maintenance Management System
– Engine oil change reminder light operation
Condition
Mileage = 35,000 km ~ 40,000 km
or
Specified Soot Volume A
Mileage = 40,000 km or more
or
Specified Soot Volume B
Engine Oil Change
Reminder Light
Model Outline
KD Series Engine
Chassis
Body
Body Electrical
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Intake Shutter Valve
– Intake shutter valve position sensor
Magnet
Hall IC
Output Voltage (V)
VC
Engine
ECU
5
VLU
E2
3.51
1
0.71
0
20
0
(Full Close)
Intake Shutter
Valve Position
Sensor
70
(Full Open)
Intake Shutter Valve
Opening Angle (°)
100
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Variable Nozzle Vane Type Turbocharger (1KD only)
– Nozzle Vane Position Sensor
• Non-contact type position sensor
Hall ICs
Magnets
Cross-section
0
-55 
55 
Output Voltage (V)
Output characteristic of
main, sub sensor
4.5
2.5
0.5
-55
0
55
Sensor shaft rotation angle ()
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Fuel Cooler
– A fuel cooler cools the return fuel
– It is used on the model equipped with an intercooler
Front
Fuel Cooler
(Aluminum)
From Supply
Pump / Injector
To Fuel Tank
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Fuel Cooler
– Construction
Fin
Cross
Section
To Fuel Tank
From
Supply Pump / Injector
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Accelerator Pedal
– Non-contact type accelerator pedal position sensor is
used
Accelerator Pedal
Position Sensor
Model Outline
Reference
KD Series Engine
Chassis
Body
Body Electrical
Accelerator Pedal
– Using magnet and hall IC
VCP1
Magnets
Output Voltage (V)
VPA1
EP1
VCP2
Hall
IC
VPA2
EP2
Accelerator
Pedal Position
Sensor
Engine
ECU
5
VPA2
VPA1
0
Full Close
Full Open
Accelerator Pedal Depressed Angle