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

2,982 (182.0)

2,492 (152.2)

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

cm3 (cu. in.)

Bore x Stroke
mm (in.)
Compression Ratio
Max. Output
kW @ rpm
Max. Torque

Nm @ 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
At low
low engine
engine speed,
speed,
SCV
is
closed
SCV is closed to
to
strengthen
the
swirl
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

Close

After the
engine
start

Nozzle vane is
controlled based
on the zero point

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

Various
Signals

Other Injectors

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
Various
Signals

EDU
Other Injectors

Max.
Max. 160MPa
160MPa

HP3
HP3 Type
Type
Fuel Pressure
Supply
Supply Sensor
Pump
Pump

Injector
Injector
compensation
compensation
code
code
Pressure
Limiter

Common-rail
Injector
Pressure
Switch

Fuel Cooler

Warning
Warning
Supplylight
light
Pump
for
for fuel
fuel filter
filter
clogging
clogging and
and
fuel
fuel sedimenter
sedimenter

SCV

Fuel
Filter

Fuel System
WarningDetects
Light
Detects

filter
filter
clogging
clogging

Element
replacement
replacement
type
type

Element
Fuel Tank

Fuel
Fuel cooler
cooler
cools
cools return
return
fuel
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

Injector
Pilot injection reduces NOx and engine noise

Body Electrical

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

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

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

Cloggin
g
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
Afterthe
thedriving
drivingfor
for30
30min.
min.or
ormore
more

Fuel Filter Warning Switch Condition

OFF
OFF for
for 10
10 min.
min.
or
more
or more

or

OFF
OFF is
is detected
detected for
for 22
times
times during
during 11 trip
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
Engine Speed
Speed
Injection
Injection Volume
Volume
Injection
Injection Timing
Timing
A/F
Ratio
A/F Ratio

Meter ECU

Soot
Volume

ODO / TRIP
Switch

Soot
Soot Volume
Volume
Calculation
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
Output Voltage (V)

Hall IC
VC

Engine
ECU

VLU

E2

5
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
pe
O
VN

2.5
0.5
-55

Cl o
N
V

se

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

Chassis

Body

Body Electrical

Accelerator Pedal
Using magnet and hall IC

VCP1
Magnets
VPA1
Output Voltage (V)

KD Series Engine

EP1
VCP2
Hall
IC

VPA2
EP2

Accelerator
Pedal Position
Sensor

Engine
ECU

5
VPA2

VPA1

0
Full Close

Full Open

Accelerator Pedal Depressed Angle