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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

Engine Overall 1KD-FTV / 2KD-FTV
TOYOTA D-4D, 3.0 / 2.5 liter, in-line 4-cylinder, 16 valve DOHC with turbocharged diesel engine TOYOTA D-4D (Direct injection 4-stroke common-rail Diesel engine) 1KD-FTV 2KD-FTV

(HILUX, FORTUNER, INNOVA)
Engine Overall 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 Fuel System Common-Rail Type Intercooler With Without / With *2 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 18.4 18.5 Max. Output rpm 3,400 3,600 3,600 *2 Max. Torque rpm ~ 3,200 1,400 ~ 3,200 1,600 ~ 2,400 *1 2,000 *2 Intercooler has been adopted on 1KD-FTV engine and it realizes higher output and torque Each of the 2KD-FTV engine and the 2KD-FTV engine (High Version) is controlled by the different programmed engine ECU to tune their output and torque *1: 2KD-FTV High Version *2: 2KD-FTV High Version (HILUX for Thai only)

Engine Overall Features Engine compartment
Rotary Solenoid Type Diesel Throttle VN Type Turbocharger (1KD only) 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 Photo: 1KD-FTV Fuel Filter Fuel filter warning (clogging detection) Element replacing type SLLC

(with intercooler model only)
Engine Overall Features Under floor Fuel Cooler (with intercooler model only) A fuel cooler cools the return fuel It is adopted only for models with intercooler Injection pressure: With intercooler model  Max. 160 MPa Without intercooler model  Max. 135 MPa Front

Ni-resist Cast Iron Ring Carrier
Engine Proper 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 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 Cooling Channel 1KD-FTV 2KD-FTV

Valve Mechanism Timing Belt
Maintenance interval: replace at every 150,000 km Oil Pump Drive Gear Camshaft Timing Pulley No. 2 Crankshaft Timing Gear Supply Pump Drive Gear Timing Belt Automatic Belt Tensioner Maintenance interval: replace at every 150,000 km Camshaft Timing Pulley No. 1 Vacuum Pump Drive Gear Idle Gear

Lubrication System Lubrication System Overall
Lubrication is fully pressurized and all oil passes through an oil cooler and oil filter Oil Filter Oil Cooler

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 Running Small - Full Open Controls EGR amount Stop Full Close Reduced noise and vibration Intake Shutter Valve Position Sensor -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 Air flow Intake Shutter Valve Rotary Solenoid type Motor

Intake Shutter Valve Construction Rotary Solenoid Type Motor Intake Shutter Valve Position Sensor Steel Layer Magnet Hall IC A quick response and high precise control are realized by driving a valve shaft directly Full Open  Full Close: 100 ms Magnet Magnet

Intake Manifold Two intake port with different shape from intake manifold to cylinder head For swirl optimizing in cylinder Two different shape of intake port in each cylinder to make optimized swirl in cylinder

Swirl Control Valve (1KD only) 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 1KD-FTV only

Swirl Control Valve (1KD only) Operation Intake Air At low engine speed, SCV is closed to strengthen the swirl Vacuum Pump Actuator Engine Speed -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 Engine ECU VSV ON / OFF Accelerator Pedal Opening

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

Variable Nozzle Vane Type Turbocharger (1KD only) Construction Exhaust Gas DC Motor Intake Air Nozzle Vane Position Sensor Turbine Wheel Reduction Gears The system is controlled by engine ECU and nozzle vane is regulated by DC motor Motor Rod Link Full-Close Stopper Nozzle Vane

Variable Nozzle Vane Type Turbocharger (1KD only) 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

Variable Nozzle Vane Type Turbocharger (1KD only) 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 Engine ECU always detects and controls the vane optimally Nozzle Vane Position Sensor

Variable Nozzle Vane Type Turbocharger (1KD only) Zero point calibration Link is bumped to full-close stopper IG ON  OFF Zero point calibration IG OFF  ON Motor Rod -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 Open Link Close Nozzle vane is controlled based on the zero point After the engine start Full-Close Stopper

Service Point (Intake and Exhaust System)
Variable Nozzle Vane Type Turbocharger (1KD only) 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 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 C D Confirm bumps D 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

Variable Nozzle Vane Type Turbocharger (1KD only) Operation movie Click! Movie

Turbocharger (2KD only) Light weight, compact and high performance turbocharger Air-cooled type Waste Gate Valve Actuator for Waste Gate Valve

Intercooler Intake air is cooled in intercooler to increase the air density Thermal Expansion Contraction Increase oxygen density Oxygen Turbocharger After turbocharger, heated intake air is cooled down to increase the air density. Thus, engine outputs higher power and torque

Intercooler Intake air is cooled in intercooler to increase the air density After turbocharger, heated intake air is cooled down to increase the air density. Thus, engine outputs higher power and torque

Fuel System Warning Light
General NE Signal G Signal Various Signals Engine ECU EDU Other Injectors Pressure Limiter Fuel Pressure Sensor Common-rail Injector Pressure Switch Common-rail Diesel system -Higher output -Low noise and vibration -Cleaner emission Fuel Cooler Fuel Filter SCV Supply Pump Fuel System Warning Light Fuel Tank

Fuel System Features NE Signal G Signal Various Signals Engine ECU EDU
Max. 160MPa HP3 Type Supply Pump Warning light for fuel filter clogging and fuel sedimenter Injector compensation code Element replacement type Detects filter clogging Fuel cooler cools return fuel Other Injectors Pressure Limiter Fuel Pressure Sensor Common-rail Injector Pressure Switch 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 Fuel Cooler Fuel Filter SCV Supply Pump Fuel System Warning Light Fuel Tank

Common-rail System General
This system realize high injection pressure in all speed range of the engine NE Signal G Signal Various Signals Engine ECU EDU (Operates injector at high-speed) Pressure Limiter Fuel Pressure Sensor Common-rail (Stores high-pressure fuel) Injector (Injects high-pressure fuel) - Common-rail Pressure - 1KD, 2KD with Intercooler: 30 – 160 MPa (306 – 1632 kgf/cm2, 4351 – psi) 2KD without Intercooler: 30 – 135 MPa (306 – 1377 kgf/cm2, 4351 – psi) SCV Supply Pump (Generates high-pressure fuel) Fuel Tank : High-pressure (Max. 160 MPa)

Reference (Common-rail System)
General Features of common-rail system Injection pressure, volume and timing are controlled electrically High accuracy engine control High pressure fuel Higher atomization of fuel High pressure injection in all engine speed range Stores high pressure fuel High performance and fuel economy Low noise and vibration Clean emission

Common-rail System System Outline System Common-rail Diesel
Conventional Diesel Injection Volume Control ECU (Injector) Pump (Governor) Injection Timing Control Pump (Timer) Injection Pressure Control Supply Pump (SCV) According to rotational speed and injection quantity Pressurization Supply Pump Pump Distribution Common-rail Injection Pressure Max. 160 MPa Approx. 15 MPa Pressure Sensor Constant high pressure ECU SCV Supply Pump Common-rail Injector Instantaneously high pressure Timer Governor Pump Injection Nozzle 160 MPa = 1632 kgf / cm2 = psi 15 MPa = 153 kgf / cm2 = 2176 psi

SCV (Suction Control Valve)
Common-rail System Location Engine Front Injection Pipe Injector Fuel Inlet Pipe Common-rail Fuel Pressure Sensor Pressure Limiter Supply Pump SCV (Suction Control Valve) Fuel Temp. Sensor

Common-rail System Supply Pump
Supplies the high pressure fuel to the common-rail Driven by crankshaft To Common-rail (Outlet) From Fuel Filter (Inlet) To Fuel Tank (Return) SCV (Suction Control Valve)

SCV (Suction Control Valve)
Common-rail System Supply Pump Construction Eccentric and Ring Cam Check Valve Delivery Valve Plunger Feed Pump HP3 type supply pump is compact and light weight design Fuel Temp. Sensor SCV (Suction Control Valve)

Common-rail System Supply Pump Construction To fuel tank (return)
Ring Cam 2-plunger, opposite type Plunger Eccentric Cam

Common-rail System Supply Pump Fuel flow To common-rail From fuel tank

Common-rail System Supply Pump Fuel flow (reference) Click! Movie

Common-rail System 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

Common-rail System Supply Pump Suction and pumping operation Click!
Movie

Fuel control operation (SCV opening small) Fuel Pumping Mass SCV adjusts fuel volume supplied to common rail and regulates internal fuel pressure

Fuel control operation (SCV opening large) Fuel Pumping Mass SCV adjusts fuel volume supplied to common rail and regulates internal fuel pressure

Supply Pump Plunger makes vacuum to suction the fuel until cavitations disappearing Negative Pressure

Fuel control operation (SCV opening small) Click! Movie

Fuel control operation (SCV opening large) Click! Movie

[Fuel Pressure Control]
Common-rail System Supply Pump The SCV opening regulates the pumping volume to control fuel pressure [Fuel Pressure Control] Fuel Pressure Sensor Common-rail pressure (Feedback) SCV Engine ECU calculates the target injection pressure (Max. 160 MPa) based on the signals from the acceleration pedal position sensor and the crankshaft position sensor (Driving condition) Engine ECU controls the SCV opening to regulate the pumping volume, so that the pressure detected by the fuel pressure sensor matches the target injection pressure - Common-rail Pressure (Target Injection Pressure) - 1KD, 2KD with Intercooler: 30 – 160 MPa (306 – 1632 kgf/cm2, 4351 – psi) 2KD without Intercooler: 30 – 135 MPa (306 – 1377 kgf/cm2, 4351 – psi) Controls SCV opening Crankshaft Position Sensor Calculation of target injection pressure Accelerator Pedal Position Sensor Engine ECU

Common-rail System Common-rail
Stores high-pressure fuel (Max. 160 MPa) produced by supply pump Pressure Limiter Fuel Pressure Sensor Pressure Limiter: Relief the fuel when pressure rises abnormally high (200 MPa) Discharge valve is discontinued from previous 2KD-FTV Common-rail From Supply Pump To Injector To Fuel Tank

Output characteristic
Common-rail System Common-rail Fuel pressure sensor Detects the internal fuel pressure of common-rail Output characteristic Sensor Tip 4.04 2.44 Output Voltage (V) 1.0 90 190 Common-rail Pressure (MPa) Common-rail Pressure

Injector Compensation Code
Common-rail System Injector High pressure injection for higher atomization Injector Compensation Code Return to Fuel Tank From Common-rail Small injection hole (0.14 mm) 1KD-FTV: 8-hole type 2KD-FTV: 6-hole type 0.14 mm

Injector High pressure injection for higher atomization Small injection hole (0.14 mm) Click! Movie

Common-rail System Injector Construction Solenoid Coil
From Common-rail Return to Fuel Tank Piston Nozzle Spring Nozzle Needle

Common-rail System Injector Controlled by engine ECU signal Solenoid
TWV Small Orifice Return From Common-rail Large Orifice No Injection -Solenoid is not energized and the TWV is closed by spring and fuel pressure. Nozzle also closes by high pressure fuel in chamber Injection Start -Solenoid operates to open TWV. Then, fuel starts to flow out of the control chamber through large orifice. -Nozzle needle rises and injection starts. -The orifice also causes the injection rate to increase gradually. Injection End -Solenoid is finished to energized and TWV is closed by the valve spring and fuel pressure. -High-pressure fuel is applied in chamber -Nozzle is closed rapidly, and sharp injection end is realized. Click! Movie

Conventional Injection Control
Common-rail System Injector Pilot injection reduces NOx and engine noise Main Injection Volume Pilot NOx and engine noise Heat Release Value Pilot injection -Inject small amount of fuel initially before main injection timing -It shortens ignition delay at the main injection -It reduces noise, vibration and emission by preventing sudden rising of combustion pressure in cylinder TDC TDC Pilot Injection Control Conventional Injection Control

Common-rail System Injector
Pilot injection reduces NOx and engine noise Pilot injection -Inject small amount of fuel initially before main injection timing -It shortens ignition delay at the main injection -It reduces noise, vibration and emission by preventing sudden rising of combustion pressure in cylinder

Common-rail System EDU (Electronic Driver Unit)
Drive the injectors at high speed EDU Battery High Voltage DC / DC Converter Command Pulse IJT #1-4 Control Circuit -EDU converts to high voltage signal by receiving the injection signal from engine ECU to realizes high response operation. -EDU outputs confirmation signal (IJF) to engine ECU to detect operation condition High-speed operation IJF Confirmation Pulse Engine ECU Injector

Common-rail System Diagnosis DTCs for common-rail system DTC No.
Trouble Area Detection Condition Fail-safe DTC No. Detection Item Trouble Area P0087 (49) Fuel Rail/System Pressure - Too Low •Open or short in fuel pressure sensor circuit •Fuel pressure sensor •Engine ECU P0088 (78) Fuel Rail/System Pressure - Too High •Short in supply pump (SCV) circuit •Supply pump (SCV) •Engine ECU P0093 (78) Fuel System Leak Detected - Large Leak •High pressure fuel line •Open or short in EDU circuit •Open or short in injector circuit •Supply pump •Common-rail •Injectors •EDU •Engine ECU P0190 (49) Fuel Rail Pressure Sensor Circuit Malfunction • Open or short in fuel pressure sensor circuit •Fuel pressure sensor •Engine ECU P0192 (49) Fuel Rail Pressure Sensor Circuit Low Input P0193 Fuel Rail Pressure Sensor Circuit High Input

1 trip detection logic for all DTC
Common-rail System Diagnosis DTCs for common-rail system Trouble Area Detection Condition Fail-safe DTC No. Detection Item Detection Condition P0087 (49) Fuel Rail/System Pressure - Too Low Fuel pressure sensor output voltage stays at fixed value P0088 (78) Fuel Rail/System Pressure - Too High Fuel pressure exceeds predetermined value P0093 (78) Fuel System Leak Detected - Large Leak Difference of common-rail pressure before and after fuel injection varies greatly from difference of value that engine ECU calculates before and after injection P0190 (49) Fuel Rail Pressure Sensor Circuit Malfunction Fuel pressure sensor output voltage is 0.55V or less, or 4.9V or more for 0.5 sec. P0192 (49) Fuel Rail Pressure Sensor Circuit Low Input Fuel pressure sensor output voltage is 0.55V or less for 0.5 sec. P0193 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

Trouble Area Detection Condition Fail-safe DTC No. Detection Item Fail-safe P0087 (49) Fuel Rail/System Pressure - Too Low Limits engine power P0088 (78) Fuel Rail/System Pressure - Too High P0093 (78) Fuel System Leak Detected - Large Leak Limits engine power for 1 min., and then stops the engine P0190 (49) Fuel Rail Pressure Sensor Circuit Malfunction P0192 (49) Fuel Rail Pressure Sensor Circuit Low Input P0193 Fuel Rail Pressure Sensor Circuit High Input

Trouble Area Detection Condition Fail-safe DTC No. Detection Item Trouble Area P0200 (97) Injector Circuit / Open •Open or short in EDU circuit •EDU •Injector •Engine ECU P0627 (78) Fuel Pump Control Circuit / Open •Open or short in (SCV) circuit •SCV P1229 Fuel Pump System •Short in supply pump (SCV) circuit •Supply pump (SCV) P1601 (89) Injector Correction Circuit Malfunction (EEPROM) •Injector compensation code

1 trip detection logic for all DTC
Common-rail System Diagnosis DTCs for common-rail system Trouble Area Detection Condition Fail-safe DTC No. Detection Item Detection Condition P0200 (97) Injector Circuit / Open Open or short in EDU or injector circuit. After engine is started, there is no injection confirmation (IJF) signal from EDU, despite engine ECU sending injection command (IJT) signal to EDU P0627 (78) Fuel Pump Control Circuit / Open Open or short in suction control valve circuit for more than 0.5 sec. P1229 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

Trouble Area Detection Condition Fail-safe DTC No. Detection Item Fail-safe P0200 (97) Injector Circuit / Open Limits engine power P0627 (78) Fuel Pump Control Circuit / Open P1229 Fuel Pump System P1601 (89) Injector Correction Circuit Malfunction (EEPROM) -

Common-rail System 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

Service Point (Common-rail System)
Supply Pump Initialization and Calibration Initialization and calibration for supply pump discharge volume EEPROM supply pump discharge characteristic data New Initialization and Calibration Replacement Rewrite pump discharge characteristic data -Initialization and calibration are required after replacement of supply pump or engine ECU. -Engine ECU learns and memorizes the supply pump discharge volume variances New Initialization is needed only when the engine can not start after replacement

Supply Pump Initialization and Calibration Procedure Initialization After replacement Engine stalls CG TC for 3 min. IG ON IG OFF STRAT DLC3 Resetting Short Engine starts Engine starts [Initialization (not using IT II)] 1, Short the TC and CG terminals of DLC3 2, IG ON 3, Wait for 3 min. 4, IG OFF NOTE: Initialization is needed only when the engine can not start after replacement When using IT II, perform the “Supply Pump Initialization” [Calibration] 1, Start and warm-up the engine (until the engine coolant temp.[THW] more than 60 °C and fuel temp.[THF] more than 20°C) (THW > 60°C = Thermostat open) (THF > 20°C = Ambient temperature > 20°C) NOTE: When using IT II, check the THW and THF value by data list 2, Idling for 1 min. after the warm-up 3, IG OFF Calibration Learning THW > 60 °C THF > 20 °C Warm-up Idling for 1 min. IG OFF

Common-rail Replacement Common-rail can not be disassemble (Assembly replacement ) Don’t remove ! Fuel Pressure Sensor NOTE: If disassembled, change common-rail assembly Pressure Limiter

Reprogramming of Injector Compensation Code Injector or engine ECU has been replaced, need reprogramming of injector compensation value Replace the Injector New Injector Number Reprogramming the Data Engine ECU Input the Numbers Replace the Engine ECU -Injector replacement: New injector’s compensation value should be reprogrammed in engine ECU -Engine ECU is changed: All of the existing injector compensation codes must be input to new engine ECU. All Injectors Number

Reprogramming of Injector Compensation Code Outline of registration operation When replace the injector(s) When replace the engine ECU Save compensation code data Replace the injector(s) code data Input the new compensation code(s) manually Replace the engine ECU Input Set After replacement of engine ECU or injector, DTC P1601 is set Input the saved compensation codes New New Saved data Clear DTC P1601 Clear DTC P1601 Registration Completion Registration Completion

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) Save the Compensation Codes NOTE: Before replacement of engine ECU, injector compensation code for all injectors should be saved in the Intelligent Tester II Click!

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) Select Powertrain  Engine and ECT Utility Injector Compensation “Next”

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) “Next”

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) “Read Compensation Code”

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) Select cylinder No.

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU)

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) “Save”

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) Check that the compensation code is correct “Save”

Reprogramming of Injector Compensation Code Save injector compensation codes (before replacement of engine ECU) Finish the No.1 cylinder’s injector compensation code saving Read and save other injector compensation codes Finish this operation

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) Set the Compensation Codes After replacement, reprogram injector compensation code which are saved Click!

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) Select Powertrain  Engine and ECT Utility Injector Compensation “Next”

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) “Next”

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) “Set Compensation Code”

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) Select cylinder No.

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) “Input” (Input manually) “Open” (Input saved data)

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) 1 30 Input the Numbers “Input” (Input manually)

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) 1 30 Input the Numbers “OK” 01BBC0DFED00E70D A2

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) “Open”

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement)

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) Check that the compensation code is correct “Next”

Reprogramming of Injector Compensation Code Registration of injector compensation codes (after replacement) Finish the No.1 cylinder’s injector compensation code setting Set other injector compensation codes Finish this operation

Replace a New Parts Non-reusable parts (in red) Nozzle Holder Seal Injector Back-up Ring O-ring Head Cover Nozzle Seat Gasket NOTE: Non reusable parts. O-ring Leakage Pipe Supply Pump

Replace a New Pipe Replace a new pipe when the following parts are replaced Injection Pipes Replaced Parts Replace a New Pipe Injector Common-rail Cylinder Head Injection Pipes Supply Pump Cylinder Block Cylinder Gasket Gear Case Fuel Inlet Pipe Fuel Inlet Pipe

Check Fuel Leak (Nozzle Leakage Pipe) Maintain 250 kPa (2.5 kgf /cm2, 35.5 psi) of pressure for 60 sec. and check no bubbles come out SST ( ) [ ] Coat the soap water to connection and no bubbles come out Nozzle Leakage Pipe 250 kPa Remove Check Valve (Part No ) SST ( )

Check Fuel Leak (Fuel System) 1, Engine Stop No Leakage 2, Cranking the engine No Leakage 3, Disconnect the return hose from common-rail Cranking the engine Without Intelligent Tester II [ Perform Fuel Leak Teat (Active Test) ] -Fully depress the accelerator pedal quickly -Make maximum engine speed and keep it for 2 sec. -Repeat this operation several times No Leakage (from return pipe) 4, Using Intelligent Tester II, perform the Fuel Leak Test (Active Test) No Leakage Fuel System is normal

Power Balance Check Use the Intelligent Tester II (Active Test) for power balance of the engine Active Test Injector Cut #1 Injector Cut #2 Injector Cut #3 Injector Cut #4 High Voltage CAUTION: Do not disconnect the injector connector while engine running because of high voltage Don’t disconnect injector connector

Fuel System Fuel Filter Replace fuel filter element only Priming
Pump Fuel Filter Warning Switch To Supply Pump From Fuel Tank Fastener Nut Filter Housing (Plastic) Fuel filter type is changed from cartridge type to element only Filter Element Drain Cock

Fuel System Fuel Filter Construction Priming
Pump Fuel Filter Warning Switch From Fuel Tank To Supply Pump Fastener Nut Filter Element Filter Housing (Plastic) Fuel filter warning is added. Basic construction is same as previous diesel engine system. -Sedimenter level warning system -Priming pump Fuel Sedimenter Level Warning Switch

Fuel System Fuel Warning System
Fuel filter clogging is detected by fuel filter warning switch Fuel Filter Warning Switch Fuel System Warning Light Clogging Fuel filter maintenance timing: Fuel system warning light in combination meter turns on when filter replacement is required. ***This warning light is for both filter warning and sedimenter warning Combination Meter Fuel Filter - Fuel Filter Maintenance Interval - Fuel system warning light has been illuminated

Fuel System Fuel Warning System System Diagram Meter ECU
Combination Meter Meter ECU Vehicle Speed Sensor Fuel Filter Warning Switch Fuel System Warning Light To Supply Pump Fuel filter warning: filter clogging detection Sedimenter warning: water level detection by float system Filter Element Fuel Filter Fuel Sedimenter Level Warning Switch

Fuel System Fuel Warning System
Fuel filter warning switch turns OFF when the filter outlet pressure decreases Fuel Filter Warning Switch Fuel Filter Warning Switch ON OFF Meter ECU Meter ECU Diaphragm To Supply Pump To Supply Pump -Fuel filter clogging system: Vacuum type sensor -Filter element is clogged, suction from supply pump generates higher negative pressure in fuel pipe. Then, switch is turned off. Filter Element Negative Pressure Normal Fuel Filter (Switch: ON) Fuel Filter Clogged Up (Switch: OFF)

1 2 Fuel System Fuel Warning System
Warning light condition for fuel filter / fuel sedimenter Warning Warning Method Priority Sedimenter Warning Blink 1 Fuel Filter Warning ON 2 Warning condition: -Sedimenter warning: blink -Fuel filter warning: stays on If the both sedimenter and fuel filter warning are detected, the warning light blinks (as sedimenter warning)

Fuel System or Fuel Warning System Detection conditions
After the driving for 30 min. or more Fuel Filter Warning Switch Condition OFF for 10 min. or more OFF is detected for 2 times during 1 trip or To prevent false alarms on a cold engine, the meter ECU starts its judgment function after the driving for 30 min. or mode Fuel Filter Warning Detection Conditions - Fuel filter warning switch is OFF for 10 min. or more - Fuel filter warning switch OFF is detected for 2 times during 1 trip (OFF for 1 sec. or more = 1 time) The warning light keeps ON until the reset operation is done

Service Point (Fuel System)
Fuel Warning System When the warning light is illuminated, replace a fuel filter and reset the warning light Remove fuel filter element Loosen the fuel cap Fuel Filter Maintenance Change fuel filter element

Fuel Warning System Remove fuel filter element Disconnect Inlet hose Fuel Level Removal: 1, Disconnect battery negative terminal 2, Loosen the fuel cap (reduce tank pressure) 3, Disconnect the fuel filter warning switch connector 4, Disconnect the hose connected to the filter inlet side 5, Connect the hose to drain cock and drain fuel inside (approx. 50 cc) Drain Cock Drain a few fuels to lower the fuel level

Fuel Warning System Remove fuel filter element Screwdriver 6, Loosen the fastener nut using screwdriver, and fully loosen by hand Loosen the fastener nut Fully loosen by hand

Fuel Warning System Remove fuel filter element / Install fuel filter Install fuel filter Element 7, Remove the filter cap 8, Remove the filter element from the case 9, Remove O-ring Installation: 1, Attach 3 new O-rings to new element and the case Case Element Attach new 3 O-rings Remove the cap and take out filter element

Fuel Warning System Install fuel filter Match Marks Match Marks 2, Install new filter element and cover the filter cap to the case NOTE: Align match mark 3, Tighten the fastener nut NOTE: Tighten the nut until match mark is aligned New Element Set a new element and install a filter cap (align match marks) Tighten the fastener nut until the match marks are aligned

Fuel Warning System Install fuel filter Inlet Hose Tighten the fuel cap 4, Connect the hose to the filter inlet side 5, Tighten the fuel cap 6, Connect battery negative terminal ***NOT connect the fuel filter warning switch connector Connect

Fuel Warning System Install fuel filter / Reset warning light Reset warning light Within sec. 3 sec. IG ON OFF Reset Operation: IG ON (The fuel filter warning switch connector should be disconnected before IG ON) Connect the fuel filter warning switch connector 3 – 60 sec. after IG ON 3 sec. after the step2, fuel system warning light is turned OFF (Completion of the reset) Connect

Fuel Warning System Install fuel filter / Reset warning light Bleed air for fuel system Hand Pump Finish After replacement of the filter, bleed the air in fuel system by priming pump

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 Roller

Charging System Alternator Pulley
Engine fluctuation absorbing mechanism One-way Clutch Locked Crankshaft Pulley Speed One-way Clutch Free Alternator Pulley Speed Engine Fluctuation Pulley Speed (rpm) Time

Service Point (Charging System)
Alternator Pulley Using a SST, when remove or install the alternator pulley SST (2 parts) Remove Shaft Pulley SST

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

Serpentine Belt Drive System
Single V-ribbed belt Idler Pulley Air Conditioner Compressor Pulley Water Pump Pulley Idler Pulley Alternator Pulley with Shock Absorbing Function Idler Pulley for Automatic Tensioner Crankshaft Pulley

Engine Control System Oil Maintenance Management System
This system determines the deterioration conditions of the engine oil Oil maintenance management system is used only for Europe models

EEPROM Engine Control System 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 Mileage EEPROM Soot Volume The soot volume and mileage is memorized in the meter ECU ODO / TRIP Switch Soot Volume Calculation Vehicle Speed

Soot calculating logic Soot Volume Retard Injection End Timing Rich Lean Advance A/F Ratio

Engine oil change reminder light operation Condition Engine Oil Change Reminder Light Mileage = 35,000 km ~ 40,000 km or Specified Soot Volume A Mileage = 40,000 km or more Specified Soot Volume B [Engine oil change reminder light operation] Blink: Mileage = 35,000 km ~ 40,000 km or attains specified soot volume A Illuminate: Mileage = 40,000 km or more or attains specified soot volume B - The mileage from reset operation - The specified soot volume A is approx. 80% of specified soot volume B

Service Point (Engine Control System)
Oil Maintenance Management System Perform the reset operation after the replacement of the engine oil OFF Reset Operation Perform the reset operation after the replacement of the engine oil The accumulated soot volume and mileage data memorized in the meter ECU can be reset by the reset operation Meter ECU Soot Volume: 0 Mileage: 0 km Engine Oil Change

Service Point (Engine Control System)
Oil Maintenance Management System Reset operation Operation LCD Display to Next Slide IG ON TRIP A ODO TRIP LCD display is in the TRIP A IG OFF [Reset Operation] 1, IG ON 2, LCD display is in the TRIP A 3, IG OFF 4, While pressing the ODO / TRIP switch, turn to IG ON 5, Hold the ODO / TRIP switch down for more than 5 sec. While pressing the ODO / TRIP switch, turn to IG ON + IG ON Blinking Hold the ODO / TRIP switch down for more than 5 sec.

Oil Maintenance Management System Reset operation
Service Point Oil Maintenance Management System Reset operation Operation LCD Display Engine oil change reminder light is turned off (LCD display indicates “000000” for about 1 sec.) or (Resetting) Turned OFF 6, Engine oil change reminder light is turned off (LCD display indicates “000000” for about 1 sec.) HINT: Meter ECU is resetting the soot volume and mileage data at “000000” display 7, LCD displays TRIP A 8, Release the ODO / TRIP switch LCD displays TRIP A TRIP A Release the ODO / TRIP switch (Reset completion)

Reference Intake Shutter Valve Intake shutter valve position sensor
Magnet Hall IC 5 VC 3.51 Output Voltage (V) Engine ECU VLU 1 0.71 Sensor uses hall IC as no contact type to ensure its durability and reliability E2 (Full Close) 20 70 (Full Open) 100 Intake Shutter Valve Position Sensor Intake Shutter Valve Opening Angle (°)

Output characteristic of main, sub sensor
Reference Variable Nozzle Vane Type Turbocharger (1KD only) 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 Vane angle is detected by its position sensor with hall IC as non contact type VN Close 0  0.5 -55  55  -55 55 Sensor shaft rotation angle ()

From Supply Pump / Injector
Reference 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

Reference Fuel Cooler Construction Cross Section Fin From To Fuel Tank
Supply Pump / Injector To Fuel Tank

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

Accelerator Pedal Using magnet and hall IC
Reference Accelerator Pedal Using magnet and hall IC VCP1 Magnets VPA1 5 EP1 VPA2 VCP2 Output Voltage (V) Hall IC VPA2 VPA1 EP2 Full Close Full Open Accelerator Pedal Position Sensor Engine ECU Accelerator Pedal Depressed Angle

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