Model Outline KD Series Engine Chassis Body Body Electrical

Contents
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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
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
kW @ rpm
120 @ 3,400
75 @ 3,600
88 @ 3,600 *
2
Max. Torque
Nm @ rpm
343 @1,400 ~
3,200
200 @ 1,400 ~ 3,200
260 @ 1,600 ~ 2,400 *
1
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
Fuel Filter
Fuel filter warning (clogging detection)
Element replacing type
SLLC
Rotary Solenoid Type
Diesel Throttle
VN Type Turbocharger
(1KD only)
Photo: 1KD-FTV
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
Ni-resist
Cast Iron
Ring Carrier
Cooling
Channel
1KD-FTV 2KD-FTV
SIRM
Ring
Carrier
Model Outline KD Series Engine Chassis Body Body Electrical
Valve Mechanism
Timing Belt
Maintenance interval: replace at every 150,000 km
Timing
Belt
Automatic
Belt
Tensioner
Camshaft
Timing
Pulley No. 2
Camshaft
Timing
Pulley No. 1
Oil Pump Drive Gear
Crankshaft Timing Gear
Supply Pump Drive Gear
Idle Gear
Vacuum Pump Drive 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 Cooler
Oil Filter
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
Condition
Valve
Position
Purpose
Starting
Full
Open
Reduced Diesel
Smoke
Running
Small -
Full
Open
Controls EGR
amount
Stop
Full
Close
Reduced noise
and vibration
Rotary Solenoid type Motor
Intake Shutter Valve
Position Sensor
Intake Shutter Valve
Air flow
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Intake Shutter Valve
Construction
Hall IC
Magnet
Magnet
Steel Layer
Magnet
Intake Shutter Valve
Position Sensor
Rotary Solenoid
Type Motor
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
Swirl Control Valve
Intake Manifold
Actuator
VSV for SCV
1KD-FTV only
Model Outline KD Series Engine Chassis Body Body Electrical
At low engine speed,
SCV is closed to
strengthen the swirl
Intake and Exhaust System
Swirl Control Valve (1KD only)
Operation
Actuator
Intake
Air
VSV
Vacuum
Pump
Engine
ECU
Accelerator
Pedal Opening
Engine Speed
ON / OFF
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
Link
Turbine
Wheel
Full-
Close
Stopper
Motor Rod
Nozzle Vane
Position Sensor
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Construction
DC Motor
Link
Nozzle Vane
Turbine
Wheel
Motor Rod
Nozzle Vane
Position Sensor
Full-
Close
Stopper
Intake Air
Reduction
Gears
Exhaust
Gas
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Construction
Drive Arm
Unison Ring
Driven Arm
Turbine
Wheel
Full-Close Stopper
Link
Motor Rod
Nozzle
Vane
Gas Flow
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Feedback Control
Nozzle
Vane
Position
Turbo Motor
Driver
Target Angle
Control Status



Engine
ECU







Turbo Pressure
Sensor
Atmospheric
Temp. Sensor
Atmospheric
Pressure
Sensor
Water Temp.
Sensor
Injector (EDU)
Crankshaft
Position Sensor
DC
Motor
Nozzle
Vane
Position
Sensor
Control
Model Outline KD Series Engine Chassis Body Body Electrical
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
Zero point calibration
IG
OFF ON
IG
ON OFF
After the
engine
start
Close
Open
Motor Rod
Full-Close
Stopper
0
Link
0
Link is bumped
to full-close
stopper
Zero point
calibration
Nozzle vane is
controlled based
on the zero point
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
Valve
Actuator
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
Turbocharger
Thermal
Expansion
Contraction
Increase
oxygen density
Oxygen
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
Fuel Pressure
Sensor
EDU
Pressure
Limiter
Supply Pump
SCV
Engine
ECU
Fuel Tank
Injector
NE Signal
G Signal
Various
Signals
Common-rail
Fuel Cooler
Pressure
Switch
Fuel
Filter
Fuel System
Warning Light
Other Injectors
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Features
Fuel Pressure
Sensor
EDU
Pressure
Limiter
Supply Pump
SCV
Engine
ECU
Fuel Tank
Injector
NE Signal
G Signal
Various
Signals
Common-rail
Fuel Cooler
Pressure
Switch
Fuel
Filter
Fuel System
Warning Light
Other Injectors
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
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
Fuel Pressure
Sensor
Pressure
Limiter
Engine
ECU
Fuel Tank
NE Signal
G Signal
Various
Signals
SCV
Supply Pump
(Generates high-pressure fuel)
Common-rail
Injector
(Injects high-pressure fuel)
EDU
(Operates injector
at high-speed)
: High-pressure (Max. 160 MPa)
(Stores high-pressure fuel)
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
System Outline
System
Common-rail Diesel Conventional Diesel
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
Pressure
Sensor
Constant high pressure
ECU
SCV
Supply Pump
Common-rail
Injector
Instantaneously high pressure
Timer
Governor
Pump
Injection
Nozzle
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Location
Common-rail
Fuel Pressure Sensor
Pressure Limiter
Supply Pump
SCV (Suction Control Valve)
Fuel Temp. Sensor
Injector
Engine
Front
Injection Pipe
Fuel Inlet Pipe
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
From Fuel Filter
(Inlet)
To Common-rail
(Outlet)
To Fuel Tank
(Return)
SCV
(Suction Control Valve)
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Construction
Plunger
Feed
Pump
Delivery
Valve
SCV (Suction
Control Valve)
Fuel
Temp.
Sensor
Check
Valve
Eccentric and
Ring Cam
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Construction
Ring Cam
Plunger
Eccentric
Cam
To fuel tank
(return)
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Supply Pump
Fuel flow
From fuel
tank
To common-rail
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
SCV
: From Feed Pump
: To Common-rail
Plunger A: Suction
Plunger B: Pumping
Plunger A: Pumping
Plunger B: Suction
Plunger A
Plunger B
Check
Valve
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
Controls
SCV
opening
Common-rail
pressure
(Feedback)
Accelerator Pedal
Position Sensor
SCV




Fuel Pressure
Sensor
Crankshaft
Position Sensor
Engine ECU
Calculation of
target injection
pressure
[Fuel Pressure Control]
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
From
Supply Pump
To Injector To Fuel Tank
Fuel
Pressure
Sensor
Pressure
Limiter
Common-rail
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
Common-rail
Pressure
0 190
1.0
4.04
Common-rail Pressure (MPa)
O
u
t
p
u
t

V
o
l
t
a
g
e

(
V
)

Output characteristic
Sensor Tip
90
2.44
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
High pressure injection for higher atomization
Injector
Compensation
Code
From
Common-rail
Return to
Fuel Tank
0.14 mm
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Construction
Nozzle
Needle
Piston
Solenoid Coil
Return to
Fuel Tank
From
Common-rail
Nozzle
Spring
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Controlled by engine ECU signal
Solenoid
Solenoid
TWV
Return
From
Common-rail
Large
Orifice
Small
Orifice
Click!
Movie
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Injector
Pilot injection reduces NOx and engine noise
TDC TDC
Pilot
Injection Control
Conventional
Injection Control
Pilot
Main
Heat
Release
Value
Injection
Volume
NOx and
engine noise
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
Engine
ECU
EDU
Injector
High
Voltage
DC / DC
Converter
Command
Pulse
Confirmation
Pulse
Battery
IJT
#1-4
IJF

Control
Circuit

High-speed
operation
Model Outline KD Series Engine Chassis Body Body Electrical
Fail-safe Detection Condition
Common-rail System
Diagnosis
DTCs for common-rail system
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
(49)
Fuel Rail Pressure Sensor
Circuit High Input
Trouble Area
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
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
(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
Detection Condition Fail-safe Trouble Area
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
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
Limits engine power
P0192
(49)
Fuel Rail Pressure Sensor
Circuit Low Input
P0193
(49)
Fuel Rail Pressure Sensor
Circuit High Input
Trouble Area Fail-safe Detection Condition
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
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
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
Fail-safe Trouble Area Detection Condition
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
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
(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
Detection Condition Trouble Area Fail-safe
Model Outline KD Series Engine Chassis Body Body Electrical
Common-rail System
Diagnosis
DTCs for common-rail system
DTC No. Detection Item Fail-safe
P0200
(97)
Injector Circuit / Open
Limits engine power P0627
(78)
Fuel Pump Control Circuit
/ Open
P1229
(78)
Fuel Pump System
P1601
(89)
Injector Correction
Circuit Malfunction
(EEPROM)
-
Fail-safe Detection Condition Trouble Area
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
Fuel Filter
Warning Switch
From Fuel Tank
To Supply Pump
Priming
Pump
Filter Housing
(Plastic)
Fastener Nut
Drain Cock







Filter Element
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Filter
Construction
Filter Element
Fuel Filter
Warning Switch
From Fuel Tank
To Supply Pump
Priming
Pump
Fuel Sedimenter Level
Warning Switch
Filter Housing
(Plastic)
Fastener Nut
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Warning System
Fuel filter clogging is detected by fuel filter warning
switch
Combination Meter
Fuel Filter
Warning Switch
Fuel System
Warning Light
Fuel Filter
- Fuel Filter Maintenance Interval -
Fuel system warning light has been illuminated
Clogging
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Warning System
System Diagram
Combination Meter
Fuel Filter
Warning Switch



Meter
ECU



Filter Element
Fuel System
Warning Light
To Supply Pump
Vehicle Speed
Sensor
Fuel Sedimenter Level Warning Switch Fuel Filter
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
Warning
Switch
To Supply Pump
Filter Element
Normal Fuel Filter
(Switch: ON)
Fuel Filter Clogged Up
(Switch: OFF)
Diaphragm
ON
Meter
ECU
Fuel Filter
Warning
Switch
To Supply Pump
OFF
Meter
ECU
Negative
Pressure
Model Outline KD Series Engine Chassis Body Body Electrical
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
Model Outline KD Series Engine Chassis Body Body Electrical
Fuel System
Fuel Warning System
Detection conditions
OFF for 10 min.
or more
OFF is detected for 2
times during 1 trip
After the driving for 30 min. or more
The warning light keeps ON until the reset operation is done
Fuel Filter Warning Switch Condition
or
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
Roller Spring
Model Outline KD Series Engine Chassis Body Body Electrical
Charging System
Alternator Pulley
Engine fluctuation absorbing mechanism
Engine
Fluctuation
Alternator
Pulley Speed
Crankshaft Pulley
Speed
P
u
l
l
e
y

S
p
e
e
d

(
r
p
m
)

Time
One-way
Clutch
Locked
One-way
Clutch
Free
Model Outline KD Series Engine Chassis Body Body Electrical
Serpentine Belt Drive System
Serpentine Belt Drive
Single V-ribbed belt
Alternator Pulley
with Shock
Absorbing Function
Water Pump
Pulley
Air Conditioner
Compressor Pulley
Idler Pulley for
Automatic Tensioner
Idler Pulley
Idler Pulley
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
Soot
Volume
ODO / TRIP
Switch
Engine ECU












Engine Oil Change
Reminder Light
Engine Speed
Injection Volume
Injection Timing
A/F Ratio
Meter ECU

Vehicle
Speed
Blink or ON
Soot Volume
Calculation
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
Oil Maintenance Management System
Soot calculating logic
A/F Ratio
Injection
End Timing
Soot
Volume
Rich
Lean
Retard
Advance
Model Outline KD Series Engine Chassis Body Body Electrical
Engine Control System
Oil Maintenance Management System
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
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
Intake Shutter Valve
Opening Angle ()
O
u
t
p
u
t

V
o
l
t
a
g
e

(
V
)

0
Engine
ECU
VC
VLU
Hall IC
Magnet
E2
0
(Full Close)
70
(Full Open)
Intake Shutter
Valve Position
Sensor
1
5
0.71
20 100
3.51
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
0 -55 55
0.5
2.5
4.5
Sensor shaft rotation angle ()
O
u
t
p
u
t

V
o
l
t
a
g
e

(
V
)

Output characteristic of
main, sub sensor
-55 55
Hall ICs
Magnets
Cross-section
0
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
From Supply
Pump / Injector
To Fuel Tank
Fuel Cooler
(Aluminum)
Front
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Fuel Cooler
Construction
From
Supply Pump / Injector
To Fuel Tank
Cross
Section
Fin
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
Accelerator Pedal Depressed Angle
Full Open Full Close
VPA1
VPA2
O
u
t
p
u
t

V
o
l
t
a
g
e

(
V
)

0
5
VCP1
VCP2
VPA2
VPA1
Hall
IC
Magnets
EP1
EP2
Engine
ECU
Accelerator
Pedal Position
Sensor