Model Outline KD Series Engine ChassisBodyBody Electrical Contents Click a Section Tab

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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-FTV2KD-FTV

Model Outline KD Series Engine ChassisBodyBody Electrical Engine Overall 1KD-FTV / 2KD-FTV Specifications Item 1KD-FTV (HILUX, FORTUNER) 2KD-FTV (HILUX, FORTUNER, INNOVA) No. of Cylinders & Arrangement4-Cylinder, In-line Valve Mechanism 16-Valve DOHC, Belt & Gear Drive Fuel SystemCommon-Rail Type IntercoolerWithWithout / With * 2 Displacement cm3 (cu. in.)2,982 (182.0)2,492 (152.2) Bore x Stroke mm (in.) 96.0 x (3.78 x 4.06) 92.0 x 93.8 (3.62 x 3.69) Compression Ratio 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 *1: 2KD-FTV High Version *2: 2KD-FTV High Version (HILUX for Thai only)

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody Electrical Engine Overall Features –Under floor Fuel Cooler (with intercooler model only) Front

Model Outline KD Series Engine ChassisBodyBody 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-FTV2KD-FTV SIRM Ring Carrier

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody Electrical 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 ChassisBodyBody 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 ChassisBodyBody Electrical Intake and Exhaust System Intake Shutter Valve –Construction Hall IC Magnet Steel Layer Magnet Intake Shutter Valve Position Sensor Rotary Solenoid Type Motor

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody Electrical Dont tighten or loosen the full-close stopper lock nut 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 1, Confirm the motor rod operates as follows after IG OFF Operation Check Time after IG OFF (sec) Motor Rod Stroke (mm) A B C D Motor Rod Full-Close Stopper Link 0 A B C D Confirm bumps 2, Confirm the link bumps to the Full- Close Stopper

Model Outline KD Series Engine ChassisBodyBody Electrical Intake and Exhaust System Variable Nozzle Vane Type Turbocharger (1KD only) –Operation movie Click! Movie

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody Electrical Intake and Exhaust System Intercooler –Intake air is cooled in intercooler to increase the air density

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

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System System Outline System Common-rail DieselConventional 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 PressurizationSupply PumpPump DistributionCommon-railPump Injection PressureMax. 160 MPaApprox. 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody Electrical Common-rail System Supply Pump –Construction Ring Cam Plunger Eccentric Cam To fuel tank (return)

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Supply Pump –Fuel flow From fuel tank To common-rail

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Supply Pump –Fuel flow (reference) Click! Movie

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

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

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

Model Outline KD Series Engine ChassisBodyBody Electrical Reference (Common-rail System) Supply Pump –Plunger makes vacuum to suction the fuel until cavitations disappearing Negative Pressure

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

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

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody Electrical Common-rail System Common-rail –Fuel pressure sensor Detects the internal fuel pressure of common-rail Common-rail Pressure Common-rail Pressure (MPa) Output Voltage (V) Output characteristic Sensor Tip

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody Electrical Reference (Common-rail System) Injector –High pressure injection for higher atomization Click! Movie

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody Electrical Common-rail System Injector –Controlled by engine ECU signal Solenoid TWV Return From Common-rail Large Orifice Small Orifice Click! Movie

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Injector –Pilot injection reduces NOx and engine noise TDC Pilot Injection Control Conventional Injection Control Pilot Main Heat Release Value Injection Volume NOx and engine noise

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Injector –Pilot injection reduces NOx and engine noise

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody Electrical Fail-safeDetection Condition Common-rail System Diagnosis –DTCs for common-rail system DTC No.Detection ItemTrouble 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 ChassisBodyBody Electrical Common-rail System Diagnosis –DTCs for common-rail system DTC No.Detection ItemDetection 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 ConditionFail-safeTrouble Area

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Diagnosis –DTCs for common-rail system DTC No.Detection ItemFail-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 AreaFail-safeDetection Condition

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Diagnosis –DTCs for common-rail system DTC No.Detection ItemTrouble 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-safeTrouble AreaDetection Condition

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Diagnosis –DTCs for common-rail system DTC No.Detection ItemDetection 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 ConditionTrouble AreaFail-safe

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Diagnosis –DTCs for common-rail system DTC No.Detection ItemFail-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-safeDetection ConditionTrouble Area

Model Outline KD Series Engine ChassisBodyBody Electrical Common-rail System Service Point for Common-rail System –Supply pump initialization and calibrationSupply pump initialization and calibration –Common-rail replacementCommon-rail replacement –Reprogramming of injector compensation codeReprogramming of injector compensation code –Replace a new partsReplace a new parts –Replace a new pipeReplace a new pipe –Check fuel leak (Leakage Pipe No.1 / Fuel System)Check fuel leak (Leakage Pipe No.1 / Fuel System) –Power Balance CheckPower Balance Check

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Supply Pump Initialization and Calibration –Initialization and calibration for supply pump discharge volume Replacement Initialization and Calibration Rewrite pump discharge characteristic data EEPROM supply pump discharge characteristic data Initialization is needed only when the engine can not start after replacement

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Supply Pump Initialization and Calibration –Procedure Initialization Calibration Idling for 1 min. DLC3 IG ON CGTC Warm-up Short for 3 min. IG OFF Resetting Learning IG OFF After replacement Engine starts Engine stalls STRAT THW > 60 °C THF > 20 °C Engine starts

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Common-rail Replacement –Common-rail can not be disassemble (Assembly replacement ) Fuel Pressure Sensor Pressure Limiter Dont remove !

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Injector or engine ECU has been replaced, need reprogramming of injector compensation value Input the Numbers Reprogramming the Data Replace the Injector Replace the Engine ECU All Injectors Number New Injector Number Engine ECU

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Outline of registration operation When replace the injector(s) When replace the engine ECU Replace the injector(s) Replace the engine ECU Save compensation code data Clear DTC P1601 Input the new compensation code(s) manually Input the saved compensation codes Registration Completion code data Saved data Clear DTC P1601 Registration Completion Input Set

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU) Save the Compensation Codes Save the Compensation Codes Click!

Model Outline KD Series Engine ChassisBodyBody Electrical Select Powertrain Engine and ECT Utility Injector Compensation Select Powertrain Engine and ECT Utility Injector Compensation Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Read Compensation Code Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Select cylinder No. Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Save Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Save Check that the compensation code is correct Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Finish this operation Read and save other injector compensation codes Finish the No.1 cylinders injector compensation code saving Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Save injector compensation codes (before replacement of engine ECU)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement) Set the Compensation Codes Set the Compensation Codes Click!

Model Outline KD Series Engine ChassisBodyBody Electrical Select Powertrain Engine and ECT Utility Injector Compensation Select Powertrain Engine and ECT Utility Injector Compensation Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Set Compensation Code Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Select cylinder No. Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Input (Input manually) Open (Input saved data) Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical 1 30 Input the Numbers Input (Input manually) Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical BBC0DFED00E70D A2 Input the Numbers OK Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Open Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Check that the compensation code is correct Next Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Finish this operation Set other injector compensation codes Finish the No.1 cylinders injector compensation code setting Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Reprogramming of Injector Compensation Code –Registration of injector compensation codes (after replacement)

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Replace a New Parts –Non-reusable parts (in red) Injector Leakage Pipe Head Cover Supply Pump O-ring Nozzle Holder Seal Gasket Nozzle Seat Back-up Ring O-ring

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Replace a New Pipe –Replace a new pipe when the following parts are replaced Replaced Parts Replace a New Pipe Injector Common-rail Cylinder Head Injection Pipes Supply Pump Common-rail Cylinder Block Cylinder Head Cylinder Gasket Gear Case Fuel Inlet Pipe Injection Pipes Fuel Inlet Pipe

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Check Fuel Leak (Nozzle Leakage Pipe) –Maintain 250 kPa (2.5 kgf /cm 2, 35.5 psi) of pressure for 60 sec. and check no bubbles come out Check Valve (Part No ) SST ( ) [ ] SST ( ) Nozzle Leakage Pipe Remove 250 kPa Coat the soap water to connection and no bubbles come out

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Check Fuel Leak (Fuel System) 1, Engine Stop No Leakage 2, Cranking the engine 3, Disconnect the return hose from common-rail Cranking the engine No Leakage 4, Using Intelligent Tester II, perform the Fuel Leak Test (Active Test) No Leakage (from return pipe) No Leakage Fuel System is normal

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Common-rail System) Power Balance Check –Use the Intelligent Tester II (Active Test) for power balance of the engine Dont disconnect injector connector Active Test Injector Cut #1 Injector Cut #2 Injector Cut #3 Injector Cut #4 High Voltage

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 SwitchFuel Filter

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody Electrical 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

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Remove fuel filter element Disconnect Inlet hose Drain a few fuels to lower the fuel level Fuel Level Drain Cock

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Remove fuel filter element Screwdriver Loosen the fastener nutFully loosen by hand

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Remove fuel filter element / Install fuel filter Remove the cap and take out filter element Install fuel filter Attach new 3 O-rings ElementCase Element

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Install fuel filter Set a new element and install a filter cap (align match marks) Match Marks New Element Tighten the fastener nut until the match marks are aligned Match Marks

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Install fuel filter Connect Inlet Hose Tighten the fuel cap

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Install fuel filter / Reset warning light Reset warning light Within sec. Connect IG ON 3 sec. OFF

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Fuel System) Fuel Warning System –Install fuel filter / Reset warning light Bleed air for fuel system Hand Pump Finish

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

Model Outline KD Series Engine ChassisBodyBody Electrical Charging System Alternator Pulley –Engine fluctuation absorbing mechanism Engine Fluctuation Alternator Pulley Speed Crankshaft Pulley Speed Pulley Speed (rpm) Time One-way Clutch Locked One-way Clutch Free

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Charging System) Alternator Pulley –Using a SST, when remove or install the alternator pulley SST (2 parts) Remove SST Pulley Shaft

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Charging System) Alternator Pulley –Alternator pulley cap is non-reusable part Alternator Pulley Cap (Non-reusable Part)

Model Outline KD Series Engine ChassisBodyBody 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 Crankshaft Pulley

Model Outline KD Series Engine ChassisBodyBody Electrical Engine Control System Oil Maintenance Management System –This system determines the deterioration conditions of the engine oil

Model Outline KD Series Engine ChassisBodyBody 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 Engine Speed Injection Volume Injection Timing A/F Ratio Meter ECU Vehicle Speed Blink or ON Soot Volume Calculation

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody 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 ChassisBodyBody Electrical Service Point (Engine Control System) Oil Maintenance Management System –Perform the reset operation after the replacement of the engine oil Reset Operatio n Meter ECU Soot Volume: 0 Mileage: 0 km OFF Engine Oil Change

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point (Engine Control System) Oil Maintenance Management System –Reset operation LCD Display Blinking Operation LCD display is in the TRIP A While pressing the ODO / TRIP switch, turn to IG ON Hold the ODO / TRIP switch down for more than 5 sec. ODO TRIP + to Next Slide IG ON IG OFF IG ON TRIP A

Model Outline KD Series Engine ChassisBodyBody Electrical Service Point Oil Maintenance Management System –Reset operation LCD Display Release the ODO / TRIP switch Engine oil change reminder light is turned off (LCD display indicates for about 1 sec.) LCD displays TRIP A Turned OFF Operation (Resetting) or TRIP A (Reset completion)

Model Outline KD Series Engine ChassisBodyBody Electrical

Model Outline KD Series Engine ChassisBodyBody Electrical Reference Intake Shutter Valve –Intake shutter valve position sensor Intake Shutter Valve Opening Angle (°) Output Voltage (V) 0 Engine ECU VC VLU Hall IC Magnet E2 0 (Full Close) 70 (Full Open) Intake Shutter Valve Position Sensor

Model Outline KD Series Engine ChassisBodyBody Electrical Reference Variable Nozzle Vane Type Turbocharger (1KD only) –Nozzle Vane Position Sensor Non-contact type position sensor Sensor shaft rotation angle () Output Voltage (V) Output characteristic of main, sub sensor VN Close VN Open Hall ICs Magnets Cross-section 0

Model Outline KD Series Engine ChassisBodyBody 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 ChassisBodyBody Electrical Reference Fuel Cooler –Construction From Supply Pump / Injector To Fuel Tank Cross Section Fin

Model Outline KD Series Engine ChassisBodyBody Electrical Reference Accelerator Pedal –Non-contact type accelerator pedal position sensor is used Accelerator Pedal Position Sensor

Model Outline KD Series Engine ChassisBodyBody Electrical Reference Accelerator Pedal –Using magnet and hall IC Accelerator Pedal Depressed Angle Full OpenFull Close VPA1 VPA2 Output Voltage (V) 0 5 VCP1 VCP2 VPA2 VPA1 Hall IC Magnets EP1 EP2 Engine ECU Accelerator Pedal Position Sensor