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

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

3. 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

4. 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
3,400
3,600
Max. Torque [EEC]
N·m / rpm
~ 3,200
1,400 ~ 3,200
1,600 ~ 2,400 *
Intercooler has been adopted on 1KD-FTV engine and it realizes higher output and torque
*: High Version
Hilux DC 2009

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

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

17. Intake and Exhaust System
VN Turbo Movie (Click!)

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

19. 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

20. 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

21. 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

22. 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

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

24. 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

25. 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

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

27. 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)

28. 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

29. 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

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