Instructor Click a Section Tab Contents Click a Section Tab Hilux DC 2009

Engine Overall Engine Proper Valve Mechanism Lubrication System Intake and Exhaust System Common-rail System Fuel System Charging System Serpentine Belt Drive System

Equipped w/ Variable Nozzle Vane Turbo Charger Instructor Engine Overall 1KD-FTV TOYOTA D-4D, 3.0 liter, in-line 4-cylinder, 16 valve DOHC with turbocharged diesel engine Equipped w/ Variable Nozzle Vane Turbo Charger TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine) 1KD-FTV Hilux DC 2009

Engine Overall 1KD-FTV Specifications Item 1KD-FTV (HILUX D-Cab) Instructor Engine Overall 1KD-FTV Specifications Item 1KD-FTV (HILUX D-Cab) 2KD-FTV (KIJANG INNOVA) No. of Cylinders & Arrangement 4-Cylinder, In-line <- Valve Mechanism 16-Valve DOHC, Belt & Gear Drive Fuel System Common-Rail Type Intercooler With Without Displacement cm3 (cu. in.) 2,982 (182.0) 2,492 (152.2) Bore x Stroke mm (in.) 96.0 x 103.0 (3.78 x 4.06) 92.0 x 93.8 (3.62 x 3.69) Compression Ratio 17.9 18.5 Max. Output [EEC] kW / rpm 120 @ 3,400 75 @ 3,600 Max. Torque [EEC] N·m / rpm 343 @1,400 ~ 3,200 200 @ 1,400 ~ 3,200 260 @ 1,600 ~ 2,400 * Intercooler has been adopted on 1KD-FTV engine and it realizes higher output and torque *: High Version Hilux DC 2009

Engine Overall Features Engine compartment Swirl Control Valve Instructor Engine Overall Features Engine compartment Swirl Control Valve Rotary Solenoid Type Diesel Throttle VN Type Turbocharger SLLC Maintenance Interval - Inspect at every 40,000km First replace at 160,000km, then replace at every 80,000km Rotary solenoid type D-throttle VN(Variable Nozzle vane) type turbocharger Fuel filter -Filter warning for maintenance -Element replacing type SLLC Fuel Filter Fuel filter warning (clogging detection) Element replacing type 9.0 liter (w/o heater) Hilux DC 2009

From Supply Pump / Injector Instructor Engine Overall 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 Fuel cooler cools the return fuel from engine Fuel cooler  with intercooler model only To Fuel Tank Hilux DC 2009

Reference Fuel Cooler Construction Cross Section Fin From To Fuel Tank Instructor Reference Fuel Cooler Construction Fin Cross Section From Supply Pump / Injector To Fuel Tank Hilux DC 2009

Diesel Fuel: cetane number 48 or higher Engine Overall Plastic Fuel Tank is used Tank capacity is 76 liter Diesel Fuel: cetane number 48 or higher

Instructor Engine Oil and Oil Filter Maintenance interval Service Point Engine Oil and Oil Filter Maintenance interval Engine 1KD-FTV and 2KD-FTV Replacement Engine Oil Normal Every 10,000km or 6 months Severe Every 5,000km or 3 months Engine Oil Filter Oil Quantity: With Filter : 6.9 liters Without Filter : 6.6 liters Oil Grade: G-DLD-10, API CF-4 or API CF You may also use API CE or CD Oil grade: API CF-4 or CF Oil capacity: With oil filter  6.9 L Without oil filter  6.6 L For the details, please refer to upcoming maintenance interval information Viscosity (SAE): 20W-50, 15W-40, 10W-30 or 5W-30 Please refer to Service Booklet for “Normal” & “Severe” conditions Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System 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 Stop Full Close Reduced noise and vibration Intake Shutter Valve Position Sensor Air flow -Rotary solenoid realizes linear control D-throttle -At the engine starting: full open -At the engine stop: full close -During the engine operation: Linear control between small and full open to ensure driving condition and EGR performance to make vacuum in intake manifold Intake Shutter Valve Rotary Solenoid type Motor Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Swirl Control Valve Swirl control valve is provided to realize clean emission Intake Manifold Actuator -1KD-FTV engine equips swirl control valve in one of the intake ports in each cylinder -This system makes strong swirl in cylinder to promotes air-fuel mixture for better combustion Swirl Control Valve VSV for SCV Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Swirl Control Valve Operation Intake Air At low engine speed, SCV is closed to strengthen the swirl Vacuum Pump Actuator Engine Speed Engine ECU -The Valve is controlled by the engine ECU through VSV -Operating condition of the valve Low engine speed: close to strengthen the swirl in the combustion chamber High engine speed: open Cold engine start: open to reduce the white smoke VSV ON / OFF Accelerator Pedal Opening Valve is closed during cold engine start, to reduce white smoke Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Variable Nozzle Vane Type Turbocharger Nozzle Vane is driven by DC motor DC Motor Nozzle Vane Position Sensor Turbine Wheel Motor Rod -Variable nozzle vane type turbocharger(1KD-FTV only) to ensure higher effectiveness in full range -Water-cooled type Link Full-Close Stopper Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Variable Nozzle Vane Type Turbocharger Construction DC Motor Reduction Gears Nozzle Vane Position Sensor Turbine Wheel Motor Rod The system is controlled by engine ECU and nozzle vane is regulated by DC motor Link Full-Close Stopper Nozzle Vane Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Variable Nozzle Vane Type Turbocharger Construction Motor Rod Gas Flow Drive Arm Turbine Wheel Depending on the engine speed, angle of vane is changed At low engine speed, vane is turned and exhaust gas is effectively applied to turbine Link Unison Ring Nozzle Vane Driven Arm Full-Close Stopper Hilux DC 2009

Intake and Exhaust System Variable Nozzle Vane Type Turbocharger Basic Principle of VN Turbo Charger

Intake and Exhaust System VN Turbo Movie (Click!)

Intake and Exhaust System Parts Location ECU TCM (A/T only) VN Turbo

Intake and Exhaust System Instructor Intake and Exhaust System Variable Nozzle Vane Type Turbocharger Feedback Control Engine ECU Injector (EDU) Target Angle Turbo Motor Driver Crankshaft Position Sensor Control Status Nozzle Vane Position Turbo Pressure Sensor Control Atmospheric Temp. Sensor Atmospheric Pressure Sensor DC Motor Water Temp. Sensor Nozzle Vane Position Sensor Engine ECU always detects and controls the vane optimally Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Variable Nozzle Vane Type Turbocharger Zero point calibration Link is bumped to full-close stopper IG ON  OFF Zero point calibration IG OFF  ON Motor Rod Open -The motor rod position is calibrated as zero point when IG is turned -Nozzle vane is controlled based on the sensor zero point -Don’t tighten or loosen the Full-Close Stopper lock nut Link Close Nozzle vane is controlled based on the zero point After the engine start Full-Close Stopper Hilux DC 2009

Don’t tighten or loosen the full-close stopper lock nut Instructor Service Point Variable Nozzle Vane Type Turbocharger After the replacement or reinstallation of the turbocharger, perform the operation check Operation Check 1, Confirm the motor rod operates as follows after IG OFF Motor Rod 10 B B Motor Rod Stroke (mm) Link A 5 A C C D Confirm bumps D Don’t tighten or loosen the full-close stopper lock nut After the replacement or reinstallation of the turbocharger, perform the operation check before engine starting 1 2 3 Time after IG OFF (sec) 2, Confirm the link bumps to the Full-Close Stopper Full-Close Stopper Don’t tighten or loosen the full-close stopper lock nut Hilux DC 2009

Intake and Exhaust System Instructor Intake and Exhaust System Intercooler Intake air is cooled in intercooler to increase the air density High Oxygen Density Thermal Expansion Contraction Oxygen From Turbocharger To Cylinder After turbocharger, heated intake air is cooled down to increase the air density. Thus, engine outputs higher power and torque Cooling Intercooler Hilux DC 2009

Intake and Exhaust System Intercooler Intake air is cooled in intercooler to increase the air density

Instructor Fuel System Please, refer to Innova 2KD New Model CD for the detail. Features NE Signal G Signal Various Signals Engine ECU EDU Injector compensation code Max. 160MPa Pressure Limiter HP3 Type Supply Pump Fuel Pressure Sensor Common-rail Pressure Switch Injector Fuel Cooler Fuel Filter Features -Two opposed type (HP3) supply pump -Higher pressure fuel (160 MPa) -QR type Injector compensation -Fuel filter warning system with segimenter -Fuel filter element replacement -Fuel cooler SCV Supply Pump Warning light for fuel filter clogging and fuel sedimenter Replacement filter element only Fuel Filter Warning Light Fuel Tank Fuel cooler cools return fuel Detects filter clogging Hilux DC 2009

Charging System Alternator Pulley Instructor Charging System Alternator Pulley In order to absorb a engine fluctuation, one-way clutch was adopted in the pulley A compact and lightweight segment conductor type alternator (SE08 type) Spring Sprag Hilux DC 2009

Service Point Alternator Pulley Using a SST, when remove or install the alternator pulley SST (09820-63020): 2 parts Remove

Alternator Pulley Alternator pulley cap is non-reusable part Service Point Alternator Pulley Alternator pulley cap is non-reusable part Alternator Pulley Cap (Non-reusable Part)

Serpentine Belt Drive System Single V-ribbed belt Air Conditioner Compressor Pulley Idler Pulley Water Pump Pulley Idler Pulley Alternator Pulley with Shock Absorbing Function Crankshaft Pulley Idler Pulley for Automatic Tensioner - Maintenance Interval - New 1KD-FTV and 2KD-FTV Inspect at first 100,000km, then inspect at every 20,000km

Output characteristic of main, sub sensor Instructor Reference Variable Nozzle Vane Type Turbocharger Nozzle Vane Position Sensor Non-contact type position sensor Hall ICs Output characteristic of main, sub sensor 4.5 Magnets VN Open Cross-section Output Voltage (V) 2.5 VN Close 0  0.5 Vane angle is detected by its position sensor with hall IC as non contact type -55  55  -55 55 Sensor shaft rotation angle () Hilux DC 2009

Accelerator Pedal Position Sensor Reference Accelerator Pedal Non-contact type accelerator pedal position sensor is used Accelerator Pedal Position Sensor