Model Outline KD Series Engine Chassis Body Body Electrical

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Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
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

1KD-FTV 2KD-FTV
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Overall
1KD-FTV / 2KD-FTV Specifications
1KD-FTV 2KD-FTV
Item (HILUX, (HILUX, FORTUNER,
FORTUNER) INNOVA)
No. of Cylinders & Arrangement 4-Cylinder, In-line
16-Valve DOHC,
Valve Mechanism
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 96.0 x 103.0 92.0 x 93.8
mm (in.) (3.78 x 4.06) (3.62 x 3.69)
Compression Ratio 18.4 18.5
Max. Output 75 @ 3,600
120 @ 3,400
kW @ rpm 88 @ 3,600 *2
200 @ 1,400 ~ 3,200
Max. Torque 343 @1,400 ~
260 @ 1,600 ~ 2,400 *1
Nm @ rpm 3,200
320 @ 2,000 *2
*1: 2KD-FTV High Version
*2: 2KD-FTV High Version (HILUX for Thai only)
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Overall
Features
Engine compartment
Rotary Solenoid Type
VN Type Turbocharger
Diesel Throttle
(1KD only)

Photo: 1KD-FTV

Fuel Filter
SLLC Fuel filter warning (clogging detection)
Element replacing type
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Overall
Features
Under floor Fuel Cooler
(with intercooler model only)

Front
Model Outline KD Series Engine Chassis Body Body Electrical
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

Cooling
Channel

1KD-FTV 2KD-FTV
Model Outline KD Series Engine Chassis Body Body Electrical
Valve Mechanism
Timing Belt
Maintenance interval: replace at every 150,000 km
Oil Pump Drive Gear
Camshaft
Timing Crankshaft Timing Gear
Pulley No. 2
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 Chassis Body Body Electrical
Lubrication System
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 Body Body Electrical
Intake and Exhaust System
Intake Shutter Valve
Rotary solenoid type intake shutter valve is used to
improve EGR performance
Engine Valve
Purpose
Condition Position
Full Reduced Diesel Intake Shutter Valve
Starting
Open Smoke Position Sensor
Small -
Controls EGR
Running Full
amount
Open
Full Reduced noise
Stop
Close and vibration

Air flow

Intake Shutter Valve

Rotary Solenoid type Motor

Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intake Shutter Valve
Construction

Rotary Solenoid
Intake Shutter Valve Type Motor
Position Sensor

Steel Layer
Magnet
Hall IC

Magnet
Magnet
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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 Body Body Electrical
Intake and Exhaust System
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 Body Electrical
Intake and Exhaust System
Swirl Control Valve (1KD only)
Operation

Intake
Air

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

Actuator Vacuum
Pump
Engine Speed

Engine
VSV ECU
ON / OFF

Accelerator
Pedal Opening
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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
Full-
Close
Stopper
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Construction Exhaust
Gas

DC Motor

Intake Air

Nozzle Vane
Position Sensor
Turbine Reduction
Wheel Gears
Motor Rod

Link
Full-
Nozzle Vane
Close
Stopper
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
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 Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Feedback Control

Injector (EDU)
Target Angle
Crankshaft
Turbo Motor
Position Sensor Driver
Engine Control Status
ECU Nozzle
Turbo Pressure Control Vane
Sensor
Position
Atmospheric Atmospheric
Temp. Sensor
DC
Pressure Motor
Sensor
Water Temp.
Sensor Nozzle
Vane
Position
Sensor
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Zero point calibration

Link is bumped
IG to full-close
ON OFF stopper

Zero point
IG calibration Motor Rod
OFF ON
Open
0
Link
Close
Nozzle vane is
After the
controlled based
engine on the zero point
start Full-Close
0 Stopper
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Operation movie

Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Turbocharger (2KD only)
Light weight, compact and high performance
turbocharger

Waste Gate Actuator

Valve for Waste
Gate Valve
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intercooler
Intake air is cooled in intercooler to increase the air
density
Thermal
Expansion Contraction
Increase
Oxygen oxygen density

Turbocharger
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intercooler
Intake air is cooled in intercooler to increase the air
density
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
General
NE Signal Engine EDU
G Signal ECU
Various Other Injectors
Signals
Pressure
Fuel Pressure Limiter
Sensor Common-rail

Injector

Pressure
Switch

Fuel Cooler
Fuel
SCV Filter
Supply Pump Fuel System
Warning Light Fuel Tank
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Features
NE Signal Engine EDU Injector
Injector
G Signal ECU
compensation
compensation
Various Other Injectors code
code
Signals
Max.
Max. 160MPa
160MPa
Pressure
HP3
HP3 Type
Type
Fuel Pressure Limiter
Supply
Supply Sensor
Pump Common-rail
Pump

Injector

Pressure
Switch

Fuel Cooler
Fuel
Fuel cooler
cooler
Fuel cools
cools return
return
SCV Filter fuel
Warning Element fuel
Supplylight
Warning light
Pump Fuel System Element
Fuel Tank
for
for fuel
fuel filter
filter WarningDetects
Light
Detects replacement
replacement
clogging
clogging and and filter
filter type
type
fuel
fuel sedimenter
sedimenter clogging
clogging
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
General
This system realize high injection pressure in all speed
range of the engine
NE Signal EDU
Engine
(Operates injector
G Signal ECU at high-speed)
Various
Signals
Fuel Pressure Pressure
Sensor Limiter
Common-rail

(Stores high-pressure fuel)

Injector
(Injects high-pressure fuel)

SCV
Supply Pump Fuel Tank
(Generates high-pressure fuel)

: High-pressure (Max. 160 MPa)

Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
System Outline
Common-rail Diesel Conventional Diesel
Constant high pressure Instantaneously high pressure
Common-rail Pressure
Sensor

System
SCV Governor
Timer
ECU

Injection
Injector Pump
Supply Pump Nozzle
Injection Volume
ECU (Injector) Pump (Governor)
Control
Injection Timing
ECU (Injector) Pump (Timer)
Control
Injection Pressure According to rotational speed
Supply Pump (SCV)
Control and injection quantity
Pressurization Supply Pump Pump
Distribution Common-rail Pump
Injection Pressure Max. 160 MPa Approx. 15 MPa
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Location
Engine
Front

Injection Pipe Injector

Fuel Inlet Pipe

Common-rail
Fuel Pressure Sensor
Supply Pump Pressure Limiter
SCV (Suction Control Valve)
Fuel Temp. Sensor
Model Outline KD Series Engine Chassis Body Body Electrical
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)
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Construction

Check Eccentric and Delivery

Valve Ring Cam Valve

Plunger
Feed
Pump

Fuel Temp.
Sensor

SCV (Suction
Control Valve)
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Construction
To fuel tank (return)

Ring Cam

Plunger

Eccentric
Cam
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel flow
To common-rail

From fuel
tank
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel flow (reference)

Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Suction and pumping operation

Plunger A: Suction Plunger A: Pumping

Plunger B: Pumping Plunger B: Suction
Check
Valve
Plunger A

SCV

Plunger B

: From Feed Pump : To Common-rail

Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Suction and pumping operation

Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel control operation (SCV opening small)

Fuel
Pumping
Mass
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel control operation (SCV opening large)

Fuel
Pumping
Mass
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel control operation (SCV opening small)

Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel control operation (SCV opening large)

Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
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
SCV (Feedback)

Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Position Sensor
Engine ECU
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Common-rail
Stores high-pressure fuel (Max. 160 MPa) produced by
supply pump
Pressure
Limiter

Fuel
Pressure
Sensor

Common-rail

From
To Injector To Fuel Tank
Supply Pump
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Common-rail
Fuel pressure sensor
Detects the internal fuel pressure of common-rail

Output characteristic
Sensor Tip

Output Voltage (V)

4.04

2.44

1.0

0 90 190
Common-rail Pressure (MPa)
Common-rail
Pressure
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
High pressure injection for higher atomization

Injector
Compensation
Code
Return to From
Fuel Tank Common-rail

0.14 mm
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Construction
Solenoid Coil

Return to From
Fuel Tank Common-rail

Piston

Nozzle
Spring

Nozzle
Needle
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Controlled by engine ECU signal

Solenoid
Solenoid

TWV
Small
Orifice Return
From
Common-rail Large
Orifice

Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Pilot injection reduces NOx and engine noise

Main
Injection Pilot
Volume

NOx and
engine noise

Heat
Release
Value

TDC TDC

Pilot Conventional
Injection Control Injection Control
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Pilot injection reduces NOx and engine noise
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
EDU (Electronic Driver Unit)
Drive the injectors at high speed

EDU
Battery High
DC / DC Voltage
Converter

Command
Pulse
IJT
#1-4
Control
Circuit High-speed
IJF
operation
Confirmation
Engine Pulse Injector
ECU
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
Trouble Area Detection Condition Fail-safe

DTC No. Detection Item Trouble Area

P0087 Fuel Rail/System Open or short in fuel pressure sensor
(49) Pressure - Too Low circuit Fuel pressure sensor Engine ECU
P0088 Fuel Rail/System Short in supply pump (SCV) circuit
(78) Pressure - Too High Supply pump (SCV) Engine ECU
High pressure fuel line
Open or short in EDU circuit
P0093 Fuel System Leak
Open or short in injector circuit
(78) Detected - Large Leak
Supply pump Common-rail Injectors
EDU Engine ECU
P0190 Fuel Rail Pressure Sensor
(49) Circuit Malfunction Open or short in fuel pressure sensor
P0192 Fuel Rail Pressure Sensor circuit
(49) Circuit Low Input Fuel pressure sensor
P0193 Fuel Rail Pressure Sensor Engine ECU
(49) Circuit High Input
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
Trouble Area Detection Condition Fail-safe

DTC No. Detection Item Detection Condition

P0087 Fuel Rail/System Fuel pressure sensor output voltage stays
(49) Pressure - Too Low at fixed value
P0088 Fuel Rail/System Fuel pressure exceeds predetermined
(78) Pressure - Too High value

Difference of common-rail pressure before

P0093 Fuel System Leak and after fuel injection varies greatly from
(78) Detected - Large Leak difference of value that engine ECU
calculates before and after injection

P0190 Fuel Rail Pressure Sensor Fuel pressure sensor output voltage is
(49) Circuit Malfunction 0.55V or less, or 4.9V or more for 0.5 sec.
P0192 Fuel Rail Pressure Sensor Fuel pressure sensor output voltage is
(49) Circuit Low Input 0.55V or less for 0.5 sec.
P0193 Fuel Rail Pressure Sensor Fuel pressure sensor output voltage is
(49) Circuit High Input 4.9V or more for 0.5 sec.
1 trip detection logic for all DTC
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
Trouble Area Detection Condition Fail-safe

DTC No. Detection Item Fail-safe

P0087 Fuel Rail/System
(49) Pressure - Too Low
Limits engine power
P0088 Fuel Rail/System
(78) Pressure - Too High

P0093 Fuel System Leak Limits engine power for 1 min., and then
(78) Detected - Large Leak stops the engine

P0190 Fuel Rail Pressure Sensor

(49) Circuit Malfunction
P0192 Fuel Rail Pressure Sensor
Limits engine power
(49) Circuit Low Input
P0193 Fuel Rail Pressure Sensor
(49) Circuit High Input
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
Trouble Area Detection Condition Fail-safe

DTC No. Detection Item Trouble Area

Open or short in EDU circuit

P0200 EDU
Injector Circuit / Open
(97) Injector
Engine ECU

Open or short in (SCV) circuit

P0627 Fuel Pump Control Circuit
SCV
(78) / Open
Engine ECU

Short in supply pump (SCV) circuit

P1229
Fuel Pump System Supply pump (SCV)
(78)
Engine ECU

Injector Correction
P1601 Injector compensation code
Circuit Malfunction
(89) Engine ECU
(EEPROM)
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
Trouble Area Detection Condition Fail-safe

DTC No. Detection Item Detection Condition

Open or short in EDU or injector circuit.
After engine is started, there is no
P0200
Injector Circuit / Open injection confirmation (IJF) signal from
(97)
EDU, despite engine ECU sending
injection command (IJT) signal to EDU

P0627 Fuel Pump Control Circuit Open or short in suction control valve
(78) / Open circuit for more than 0.5 sec.

Fuel over-feed:
P1229 Fuel pressure continues exceeding target
Fuel Pump System
(78) fuel pressure despite engine ECU closing
SCV
Injector Correction
P1601 Injector compensation code is not
Circuit Malfunction
(89) registered
(EEPROM)
1 trip detection logic for all DTC
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
Trouble Area Detection Condition Fail-safe

DTC No. Detection Item Fail-safe

P0200
Injector Circuit / Open
(97)

P0627 Fuel Pump Control Circuit Limits engine power

(78) / Open

P1229
Fuel Pump System
(78)

Injector Correction
P1601
Circuit Malfunction -
(89)
(EEPROM)
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Filter
Replace fuel filter element only
Priming Fuel Filter
Pump Warning Switch

To Supply Pump
From Fuel Tank

Fastener Nut

Filter Housing
(Plastic)

Filter Element

Drain Cock
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Filter
Construction
Priming Fuel Filter
Pump Warning Switch

From Fuel Tank To Supply Pump

Fastener Nut

Filter Element Filter Housing

(Plastic)

Fuel Sedimenter Level

Warning Switch
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
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 Chassis Body Body Electrical
Fuel System
Fuel Warning System
System Diagram
Combination Meter

Vehicle Speed
Sensor
Fuel Filter Meter
Warning Switch ECU
Fuel System
Warning Light

To Supply Pump

Filter Element

Fuel Filter Fuel Sedimenter Level Warning Switch

Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Warning System
Fuel filter warning switch turns OFF when the filter
outlet pressure decreases
Fuel Filter Fuel Filter
Warning Warning
Switch Switch
ON Meter OFF Meter
ECU ECU

Diaphragm

To Supply Pump To Supply Pump

Filter Element Negative

Pressure

Normal Fuel Filter Fuel Filter Clogged Up

(Switch: ON) (Switch: OFF)
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Warning System
Warning light condition for fuel filter / fuel sedimenter

Warning
Warning Priority
Method

Sedimenter
Warning 1
Blink

Fuel Filter
Warning 2
ON
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
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. OFF
OFF is
is detected
detected for
for 22
or more
or more
or times
times during
during 11 trip
trip

The warning light keeps ON until the reset operation is done

Model Outline KD Series Engine Chassis Body Body Electrical
Charging System
Alternator Pulley
In order to absorb a engine fluctuation, one-way
clutch was adopted in the pulley

Spring Roller
Model Outline KD Series Engine Chassis Body Body Electrical
Charging System
Alternator Pulley
Engine fluctuation absorbing mechanism

One-way Crankshaft Pulley

Clutch Speed
Locked

One-way
Clutch
Free

Alternator
Pulley Speed
Pulley Speed (rpm)

Engine
Fluctuation

Time
Model Outline KD Series Engine Chassis Body Body Electrical
Serpentine Belt Drive System
Serpentine Belt Drive
Single V-ribbed belt

Idler Pulley
Air Conditioner
Compressor Pulley

Water Pump
Idler Pulley Pulley

Alternator Pulley
with Shock
Absorbing Function

Idler Pulley for

Automatic Tensioner
Crankshaft Pulley
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
Oil Maintenance Management System
This system determines the deterioration conditions of
the engine oil
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
Oil Maintenance Management System
System diagram and general operation

Engine Oil Change

Engine ECU Reminder Light

Engine
Engine Speed
Speed Blink or ON
Injection
Injection Volume
Volume
Injection
Injection Timing
Timing Meter ECU
A/F Ratio
A/F Ratio

Soot
Volume ODO / TRIP
Switch
Soot
Soot Volume
Volume
Calculation
Calculation

Vehicle
Speed
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
Oil Maintenance Management System
Soot calculating logic

Soot
Volume

Retard

Injection
Rich End Timing
Lean Advance
A/F Ratio
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
Oil Maintenance Management System
Engine oil change reminder light operation

Engine Oil Change

Condition
Reminder Light

Mileage = 35,000 km ~ 40,000 km

or
Specified Soot Volume A

Mileage = 40,000 km or more

or
Specified Soot Volume B
Model Outline KD Series Engine Chassis Body Body Electrical
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Intake Shutter Valve
Intake shutter valve position sensor

Magnet
Hall IC 5

Output Voltage (V)

VC 3.51

VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full Open)
Intake Shutter
Intake Shutter Valve
Valve Position Opening Angle ()
Sensor
Model Outline KD Series Engine Chassis Body Body Electrical
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

Output Voltage (V)

4.5

n
Magnets Ope
Cross-section 2.5 VN
se
N Cl o
0 V
0.5

-55 55 -55 0 55
Sensor shaft rotation angle ()
Model Outline KD Series Engine Chassis Body Body Electrical
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

To Fuel Tank
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Fuel Cooler
Construction

Fin

Cross
Section

To Fuel Tank From

Supply Pump / Injector
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Accelerator Pedal
Non-contact type accelerator pedal position sensor is
used
Accelerator Pedal
Position Sensor
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Accelerator Pedal
Using magnet and hall IC

VCP1
Magnets
VPA1

Output Voltage (V)

EP1 5

VPA2
VCP2

Hall
IC VPA2
VPA1
EP2 0
Full Close Full Open
Accelerator Engine Accelerator Pedal Depressed Angle
Pedal Position ECU
Sensor