ENGINE
ENGINE – – 1KD-FTV AND 2KD-FTV ENGINES1KD-FTV AND 2KD-FTV ENGINES
1KD-FTV AND 2KD-FTV ENGINES
1KD-FTV AND 2KD-FTV ENGINES
DESCRIPTION
DESCRIPTION
1KD-FTV TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine) and 2KD-FTV 1KD-FTV TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine) and 2KD-FTV
TOYOTA D-4D are 3.0/2.5 liter, in-line 4-cylinder, 16-valve DOHC with turbocharged diesel engine. TOYOTA 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, clean These engines uses direct injection system and common-rail system to realize higher performance, clean
emission, low noise and low vibration. emission, low noise and low vibration.
A 2KD-FTV High Version, which has a higher power output than the normal 2KD-FTV engine, is also A 2KD-FTV High Version, which has a higher power output than the normal 2KD-FTV engine, is also
available. The 2KD-FTV and 2KD-FTV High Version engines are equipped with engine ECUs available. The 2KD-FTV and 2KD-FTV High Version engines are equipped with engine ECUs containing engine control programs that differ from each other. However, both engine models share the containing engine control programs that differ from each other. However, both engine models share the same mechanical components.
same mechanical components.
An intercooler is provided on all 1KD-FTV engine models and the 2KD-FTV High Version engine for An intercooler is provided on all 1KD-FTV engine models and the 2KD-FTV High Version engine for
Thailand. This lowers the intake
Thailand. This lowers the intake air temperature and improves power output.air temperature and improves power output.
The basic construction and operation of both the 1KD-FTV and 2KD-FTV engines are the same. For The basic construction and operation of both the 1KD-FTV and 2KD-FTV engines are the same. For
details, see "Major Difference" on page EG-114. details, see "Major Difference" on page EG-114.
1KD-FTV Engine1KD-FTV Engine
2KD-FTV Engine without Inter Cooler2KD-FTV Engine without Inter Cooler
271EG98 271EG98 271EG97 271EG97
ENGINE
ENGINE – – 1KD-FTV AND 2KD-FTV ENGINES1KD-FTV AND 2KD-FTV ENGINES
Engine SpecificationsEngine Specifications
Engine
Engine Type Type 1KD-FTV1KD-FTV 2KD-FTV2KD-FTV 2KD-FTV2KD-FTV High Version High Version No. of Cyls. &
No. of Cyls. & ArrangemArrangement ent 4-Cylinder, 4-Cylinder, In-lineIn-line
V
Valve alve MechanismMechanism 16-V16-Valve DOHC,alve DOHC, Belt & Gear Drive
Belt & Gear Drive
Combusti
Combustion on Chamber Chamber Direct Direct InjectioInjection n TypeType
Manifolds Cross-flow
Manifolds Cross-flow
Fuel
Fuel System System Common-Rail Common-Rail TypeType
Displacement cm
Displacement cm33(cu. (cu. in.) in.) 2,982 2,982 (182.0)(182.0) 2,494 (152.2)2,494 (152.2)
Bore
Bore Stroke Stroke mm (in.)mm (in.) 96.096.0 103.0 103.0
(3.78 (3.78 4.06) 4.06) 92.0 92.0 93.8 93.8 (3.62 (3.62 3.69) 3.69) Compression
Compression Ratio Ratio 17.9 17.9 : : 11 18.5 : 118.5 : 1
Max.
Max. Output Output [SAE-NET] [SAE-NET] 120 120 kW kW @ @ 3,400 3,400 rpm rpm 75 75 kW kW @ @ 3,600 3,600 rpmrpm 75 kW @ 3,600 rpm75 kW @ 3,600 rpm 88 kW @ 3,600 rpm* 88 kW @ 3,600 rpm*55
Max.
Max. Torque Torque [SAE-NET][SAE-NET] 343 N343 Nm @m @ 1,400 ~ 3,200 rpm 1,400 ~ 3,200 rpm 200 N 200 Nm @m @ 1,400 ~ 3,200 rpm 1,400 ~ 3,200 rpm 260 N 260 Nm @m @ 1,600 ~ 2,400 rpm 1,600 ~ 2,400 rpm 320 N 320 Nm @m @ 2,000 rpm* 2,000 rpm*55 Valve Valve Timing Timing Intake
Intake OpenOpen 22
BTDC BTDC
Close
Close 3737 ABDC ABDC 3131 ABDC ABDC
Exhaust Exhaust
Open
Open 4545 BBDC BBDC 3030 BBDC BBDC
Close
Close 00 A ATDCTDC
Firing
Firing Order Order 1-3-4-21-3-4-2
Fuel
Fuel Cetan Cetan Number Number 50 50 or or higherhigher
Oil
Oil Grade Grade CF-4, CF-4, 10W-3010W-30
Emission Regulation Emission Regulation
EURO III*
EURO III*22 EURO III*EURO III*55 EURO EURO III*III*88 EURO I*
EURO I*33 EURO I*EURO I*66 EURO EURO I*I*99 Tier 1*
Tier 1*44 **77 **1010
Engi
Engine Serne Service vice MassMass**
(Reference) kg (Reference) kg (lb) (lb) 260 (573) 260 (573) 223 (492)223 (492) 222 (489)222 (489) *
*11: We: Weight shows the figure with ight shows the figure with the oil and the oil and water fully filled.water fully filled. *
*22: for : for Thai, AustraThai, Australian, and Central and lian, and Central and South AmSouth American Modelserican Models *
*33: for : for Philippine, and Central and South AmericaPhilippine, and Central and South American Models (only for n Models (only for export package models)export package models) *
*44: for : for Central and South American Models (only for Central and South American Models (only for Brazilian-spBrazilian-spec models)ec models) *
*55: for Thai Models: for Thai Models *
*66: for Philippine Models: for Philippine Models *
*77: for : for General Countries ModelsGeneral Countries Models *
*88: for Thai, : for Thai, and Central and South Americand Central and South American Modelsan Models *
*99: for : for Malaysian ModelsMalaysian Models *
ENGINE
ENGINE – – 1KD-FTV AND 2KD-FTV ENGINES1KD-FTV AND 2KD-FTV ENGINES
Engine SpecificationsEngine Specifications
Engine
Engine Type Type 1KD-FTV1KD-FTV 2KD-FTV2KD-FTV 2KD-FTV2KD-FTV High Version High Version No. of Cyls. &
No. of Cyls. & ArrangemArrangement ent 4-Cylinder, 4-Cylinder, In-lineIn-line
V
Valve alve MechanismMechanism 16-V16-Valve DOHC,alve DOHC, Belt & Gear Drive
Belt & Gear Drive
Combusti
Combustion on Chamber Chamber Direct Direct InjectioInjection n TypeType
Manifolds Cross-flow
Manifolds Cross-flow
Fuel
Fuel System System Common-Rail Common-Rail TypeType
Displacement cm
Displacement cm33(cu. (cu. in.) in.) 2,982 2,982 (182.0)(182.0) 2,494 (152.2)2,494 (152.2)
Bore
Bore Stroke Stroke mm (in.)mm (in.) 96.096.0 103.0 103.0
(3.78 (3.78 4.06) 4.06) 92.0 92.0 93.8 93.8 (3.62 (3.62 3.69) 3.69) Compression
Compression Ratio Ratio 17.9 17.9 : : 11 18.5 : 118.5 : 1
Max.
Max. Output Output [SAE-NET] [SAE-NET] 120 120 kW kW @ @ 3,400 3,400 rpm rpm 75 75 kW kW @ @ 3,600 3,600 rpmrpm 75 kW @ 3,600 rpm75 kW @ 3,600 rpm 88 kW @ 3,600 rpm* 88 kW @ 3,600 rpm*55
Max.
Max. Torque Torque [SAE-NET][SAE-NET] 343 N343 Nm @m @ 1,400 ~ 3,200 rpm 1,400 ~ 3,200 rpm 200 N 200 Nm @m @ 1,400 ~ 3,200 rpm 1,400 ~ 3,200 rpm 260 N 260 Nm @m @ 1,600 ~ 2,400 rpm 1,600 ~ 2,400 rpm 320 N 320 Nm @m @ 2,000 rpm* 2,000 rpm*55 Valve Valve Timing Timing Intake
Intake OpenOpen 22
BTDC BTDC
Close
Close 3737 ABDC ABDC 3131 ABDC ABDC
Exhaust Exhaust
Open
Open 4545 BBDC BBDC 3030 BBDC BBDC
Close
Close 00 A ATDCTDC
Firing
Firing Order Order 1-3-4-21-3-4-2
Fuel
Fuel Cetan Cetan Number Number 50 50 or or higherhigher
Oil
Oil Grade Grade CF-4, CF-4, 10W-3010W-30
Emission Regulation Emission Regulation
EURO III*
EURO III*22 EURO III*EURO III*55 EURO EURO III*III*88 EURO I*
EURO I*33 EURO I*EURO I*66 EURO EURO I*I*99 Tier 1*
Tier 1*44 **77 **1010
Engi
Engine Serne Service vice MassMass**
(Reference) kg (Reference) kg (lb) (lb) 260 (573) 260 (573) 223 (492)223 (492) 222 (489)222 (489) *
*11: We: Weight shows the figure with ight shows the figure with the oil and the oil and water fully filled.water fully filled. *
*22: for : for Thai, AustraThai, Australian, and Central and lian, and Central and South AmSouth American Modelserican Models *
*33: for : for Philippine, and Central and South AmericaPhilippine, and Central and South American Models (only for n Models (only for export package models)export package models) *
*44: for : for Central and South American Models (only for Central and South American Models (only for Brazilian-spBrazilian-spec models)ec models) *
*55: for Thai Models: for Thai Models *
*66: for Philippine Models: for Philippine Models *
*77: for : for General Countries ModelsGeneral Countries Models *
*88: for Thai, : for Thai, and Central and South Americand Central and South American Modelsan Models *
*99: for : for Malaysian ModelsMalaysian Models *
ENGINE
ENGINE – – 1KD-FTV AND 2KD-FTV ENGINES1KD-FTV AND 2KD-FTV ENGINES
MAJOR DIFFERENCE
MAJOR DIFFERENCE
The table below lists the major differences between the 1KD-FTV and 2KD-FTV engines. The table below lists the major differences between the 1KD-FTV and 2KD-FTV engines.
Section Item Section Item -FTV-FTV1KD1KD -FTV-FTV2KD2KD 2KD 2KD -FTV -FTV High High Version Version Engine Proper Engine Proper
A SIRM (Sintered Iron Reinforced Material) ring carrier is A SIRM (Sintered Iron Reinforced Material) ring carrier is used in the top ring groove of t
used in the top ring groove of the piston.he piston. The piston skirt has been coated with
The piston skirt has been coated with resin.resin.
An Ni-resist cast iron ring carrier is used in the top ring An Ni-resist cast iron ring carrier is used in the top ring groove of the piston.
groove of the piston.
A PVD (Physical Vapor Deposition) coating has been A PVD (Physical Vapor Deposition) coating has been applied on the surface of the
applied on the surface of the No. 1 compression ringNo. 1 compression ring **
1
1
* *11 2 balance shafts are used.
2 balance shafts are used.
Intake and Intake and Exhaust System Exhaust System
A swirl control valve is used
A swirl control valve is used
A variable nozzle vane type turbocharger is used.
A variable nozzle vane type turbocharger is used.
Air cooled type turbocharger is used.
Air cooled type turbocharger is used.
An inter cooler is used.
An inter cooler is used. **22
An oxidation catalytic converter is used.
An oxidation catalytic converter is used. **33 **33 **22 Fuel
Fuel System System Fuel Fuel cooler cooler is is used.used. **22
Charging Charging System
System A segment conductor type alternator is used.A segment conductor type alternator is used. **
4 4
**44 Starting
Starting System System Planetary Planetary reduction reduction type type with intewith interpolar rpolar magnemagnet is t is used.used. **55 **55
Engine Control Engine Control System
System
An EGR valve position sensor is
An EGR valve position sensor is used.used. **66 **66
An air flow meter is used.
An air flow meter is used.
Swirl control system is used.
Swirl control system is used.
Turbocharger control system is used.
Turbocharger control system is used.
*
*11: Only : Only for emission regulation non-compliance modelsfor emission regulation non-compliance models *
*22: Only for Thai Models: Only for Thai Models *
*33: Only for EURO III or Tier 1 Compliance Models: Only for EURO III or Tier 1 Compliance Models *
*44: except Central and : except Central and South AmSouth American Modelserican Models *
*55: Only : Only for Central and for Central and South AmSouth American Modelserican Models *
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
FEATURES OF 1KD-FTV AND 2KD-FTV ENGINES
The 1KD-FTV and 2KD-FTV engines have achieved the following performance through the adoption of the 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)
Engine Proper
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
Mechanism A shim-less type valve lifter is used. Cooling
System 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 meter are 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.
Fuel System
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 be
replaced, has been adopted.
A fuel filter warning switch that detects the clogging of the
fuel filter has been adopted.
Charging
System A segment conductor type alternator is used. Starting
System Planetary reduction type with interpolar magnet is used. Engine
Control System
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.
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
ENGINE PROPER
1. Cylinder Head Cover
The cylinder head cover is made of plastic to
reduce weight and noise.
A baffle plate is provided on the inside of the
cylinder head cover to reduce the consumption of 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 excellent
sealing 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 A A 271EG101 A B C D E Rear A A Front Shim Cylinder Bore Side
A – A Cross Section
Outer Side
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
3. Cylinder Head
The cylinder head is made of aluminum alloy. The injector has been located in the center of the
combustion 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 by
optimizing 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 by using 2 balance shafts to cancel the imbalanced inertial force, thereby reducing engine noise (booming noise).
These balance shafts are built into the cylinder block. Driven by the timing gear, the balance shafts
rotate 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 cast iron ring carrier.
On 1KD-FTV engine models and emission regulation non-compliance 2KD-FTV engine models, a
PVD (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 Channel 271EG103 Resin Coating
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
9. Crankshaft Pulley
The rigidity of the torsional damper rubber has
been optimized to reduce noise. Torsional Damper
Rubber
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
VALVE MECHANISM
1. General
Each cylinder has 2 intake valves and 2 exhaust valves. Intake and exhaust efficiency is increased by
means 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 t he exhaust camshaft is driven through gear on the
intake camshaft.
Small-diameter, and flat-teeth gears are used for driving the exhaust camshaft in order to reduce gear
noise.
Gears Exhaust Camshaft
Intake Camshaft Timing Belt
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 contact
surface 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.
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
4. Timing Gear Train
The supply pump, vacuum pump, oil pump and balance shafts* are driven by the crankshaft timing
gear.
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 Gear Crankshaft Timing Gear Oil Pump Drive Gear 271EG161 Balance Shaft Drive Gear* Camshaft Timing Pulley No.1 Automatic Tensioner
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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-Pass Valve By-Pass Valve Relief Valve Oil Filter Oil Cooler Oil Pump Oil Strainer 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.1 Balance Shaft Journal No.2 Balance Shaft Journal Drive Gear Thrust Washer Drive Gear Thrust Washer Intake Camshaft Journal Exhaust Camshaft Journal Orifice Cam Gear Valve Lifter Valve Lifter
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 Connecting Rod Gear Oil Jet Vacuum Pump Idle Gear Oil Pan Oil Jet Piston Turbo-Charger Intake Camshaft Journal Exhaust Camshaft Journal Orifice CHECK VALVE Crankshaft Journal No.2-5 Idle Gear Shaft Cam Gear Valve Lifter Valve Lifter 271EG110
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
2. Piston Oil Jet
Piston oil jets are provided at the bottom of the cylinder block to spray oil to the piston’s cooling
channel, 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 contact
with external air.
A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature
distribution 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 the
conventional model, controls the fan speed in three stages to improve cooling performance and reduce cooling fan noise.
The TOYOTA genuine Super Long Life Coolant (SLLC) has been adopted. As a result, the
maintenance interval has been extended.
Specifications
Transmission Type MT AT
Engine Coolant
Type TOYOTA 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 Temperature
C (F) 80-84 (176-183)
*1: Models with Heater *2: Models without Heater
Reservoir Tank
Radiator
Thermostat
Oil Cooler
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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
Maintenance Intervals
First Time 160,000km (100,000miles) Every 40,000 km (24,000 miles) or 24 months whichever comes first Subsequent Every 80,000 km (50,000 miles)
SLLC is pre-mixed (50% coolant and 50% deionized water), so no dilution is needed when adding or
replacing 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 Core Thermostat Water Inlet 271EG114 Cylinder Block Reservoir Tank
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 for
Thailand.
An EGR system is provided on the models complying with the emission regulations (EURO III, EURO
I, and Tier 1). This system is designed to reduce and control NOx formation through a slight reduction of peak temperature in the engine combustion chamber, which is accomplished by introducing a small amount 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 1
emission regulation. Intercooler 271EG115 Exhaust Manifold Air Cleaner Turbocharger
Intake Shutter Assembly
Intake Shutter Valve
(Throttle Valve) EGR Valve
Intake Manifold Oxidation Catalytic Converter
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 torque motor (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 air
intake 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 Valve
Position Sensor
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 for
weight reduction.
A dual construction, high-frequency cavity resonator is used for the pipe between the turbocharger and
the intercooler.
5. EGR Valve
An EGR valve is provided midstream in the intake air passage. By cooling the EGR valve in this
manner, 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 the engine 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
6. Turbocharger
General
A variable nozzle vane type turbocharger is used for 1KD-FTV engine. A water jacket is provided in
the 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 operates mechanically in accordance with the turbo pressure.
1KD-FTV Engine
2KD-FTV Engine without Intercooler
Water Jacket Turbine Wheel Compressor Wheel DC Motor DC Motor Nozzle Vane Position Sensor 271EG121 Turbine Wheel Compressor Wheel
Wastegate Valve 271EG154
Only for 2KD-FTV Engine Models
The engine ECU determines altitude using the atmospheric pressure sensor. If the sensor indication value 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 is
driven 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 the Hilux Repair Manual.
*: Varies in accordance with altitude. As the altitude increases (the atmospheric pressure sensor Service Tip
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES Variable Nozzle Vane type Turbocharger
Variable nozzle vane type turbocharger consists primarily of an impeller, turbine, nozzle vane, unison
ring, DC motor and nozzle vane position sensor.
This turbocharger has realized great improvements in low-speed torque, maximum output, fuel
consumption, and emission reduction. These improvements have been accomplished through variable control 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 charger
housing, 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 the
flow velocity of the exhaust gas is controlled by the opening. In such a time like idling, when the exhaust gas is less, the nozzle vane is almost fully closed, but as there is a slight clearance between the 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 and exhaust emission regulation compliance.
Emission Regulation EURO III or Tier 1 EURO 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 Oxidation Catalytic Converter Integrated with Front Exhaust Pipe
Below Exhaust Manifold Main Muffler Oxidation Catalytic Converter Gasket Main Muffler Oxidation Catalytic Converter Gasket 271EG122 271EG151 1KD-FTV Engine and 2KD-FTV Engine with Intercooler
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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-precision
control.
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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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) in order 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
SCV Supply
Pump
Fuel Temp. Sensor
Fuel Filter Warning Light Fuel Filter Fuel Cooler* EDU Engine ECU NE Signal G Signal Pressure Switch Fuel Tank 271EG124
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES 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 by reducing 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 DLC3 connector, and leave the ignition switch ON for approximately 3 minutes to r eset the learned value.
After resetting, start the engine, allow it to idle* for approximately 1 minute, and turn the ignition
switch 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES 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 271EG157 271EG158 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)
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES 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. As
a 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 signals
from 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES Common-Rail
The function of the common-rail is to store the fuel that has been pressurized by the supply pump. The
common-rail is provided with a fuel pressure sensor, which detects the fuel pressure in the common-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 new
one as well. The parts that require the replacement of a pipe are listed below. Injection Pipe: Injector, Common-rail, and Cylinder Head
Fuel 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
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES Injector
1) General
An injector consists of a nozzle needle, piston,
and solenoid valve.
An injector compensation value and QR (Quick
Response) code containing encoded characteristics of the injector are printed on each injector.
The injector compensation value and QR code
contain various pieces of information regarding the injector, such as model code, and injection volume correction.
If the engine ECU is replace, use the intelligent tester II and input the injector compensation
values of all 4 injectors. If the injector is replaced, input the injector compensation value of the replaced 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 Repair
Manual.
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, allows
omni-directional, high-speed reading of large amounts of data.
QR code encodes many types of date such as numeric, alphanumeric, kanji, kana and binary
code. 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 greater volume of information than a bar code.
271EG152 Nozzle Needle Piston Solenoid Valve QR Code Injector Compensation Value 271EG153
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES 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)
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
3. Fuel Filter
General
The conventional fuel filter consists of a fuel filter element integrated with the fuel filter housing. By
contrast, 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 filter increases 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 the
fuel filter warning switch OFF signal), it determines that the fuel filter has become clogged. Then, it illuminates the fuel filter warning light on the combination meter to urge the driver to replace the fuel filter. For details on fuel filter warning light control, see page BE-XX.
271EG129
Fuel Filter
Warning Light Meter ECU Combination Meter Fuel Filter Warning Switch Diaphragm from Fuel Tank to Supply Pump Filter Element Fuel Filter Meter ECU Combination Meter
Normal Fuel Filter Fuel Filter Clogged Up
Negative Pressure Vacuum Fuel Filter Fuel Filter Warning Switch Filter Element Filter Housing Fuel Sedimenter Level Warning New Conventional Fuel Sedimenter Level Warning
Fuel Filter Assembly
Filter Element
Priming Pump Priming
Pump
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
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 viscosity that is caused by the rise in fuel temperature, and improves the reliability of the fuel system.
A
A A-A Cross Section
to
Fuel Tank from
Common-Rail
ENGINE – 1KD-FTV AND 2KD-FTV ENGINES
CHARGING SYSTEM
As on the 2TR-FE engine model, a compact and
lightweight segment conductor type alternator (SE08 type) that generates a high amperage output in a highly efficient manner has been adopted as standard equipment on models except the Central and South American models. For details on this alternator, see page EG-28.
The Central and South American models have
adopted the conventional (KCB1 type) alternator made by Bosch.
A one-way clutch function has been provided in
the pulley of 2 type alternators to absorb the fluctuations in the engine speed, thus significantly 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 an
interpolar magnet (DW2.2 type) has been adopted on the Central and South American models (except KUN26L-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 R2.7
type).
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
