diesel

ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-194

JENGINE CONTROL SYSTEM

1. General

The engine control system of the 1KD-FTV and 2KD-FTV engines has the following system.

System Outline 1KD FTV 2KD FTV

2KD-FTVHigh Version

System Outline 1KD-FTV 2KD-FTVWithoutIntercooler

WithIntercooler

Fuel InjectionVolume Control(See Page EG-206)

Based on the signals received from thesensors, the ECM determines the fuelinjection volume in accordance with theengine condition.

f f f f

Fuel InjectionTiming Control(See Page EG-207)

Based on the signals received from thesensors, the ECM determines the fuelinjection timing in accordance with theengine condition.

f f f f

During StartingControl(See Page EG-208)

To facilitate startability, the ECM optimallycontrols the injection volume and injectiontiming during starting.

f f f f

Idle Speed Control(See Page EG-209)

The ECM determines the idle speed inaccordance with the engine condition, andcontrols the fuel injection volume in order tomaintain the target idle speed.

f f f f

Fuel PressureControl

Based on the signals received from thesensors, the ECM controls fuel pressureusing the SCV (Suction Control Valve) andpressure discharge valve according toengine operating conditions.

f*1 — — —

Control(See Page EG-210) Based on the signals received from the

sensors, the ECM controls fuel pressureusing the SCV according to engineconditions.

f*2 f f f

Pilot InjectionControl(See Page EG-214)

Based on the signals received from thesensors, the ECM determines pilot injectionvolume/timing, and interval (between pilotinjection and main injection) in accordancewith the engine condition.

f f f f

Glow Plug ControlControls the length of time when the currentis applied to the glow plugs, in accordancewith the coolant temperature.

f f f f

Intake ShutterControl(See Page EG-215)

D Controls the intake shutter valve (throttlevalve) opening angle in accordance withthe engine condition.

D Fully closes the intake shutter valve(throttle valve) in order to reduce thevibration when the engine is stopped.

f f f f

(Continued)

*1: Models compliant with EURO IV emission regulations*2: Except models compliant with EURO IV emission regulations

EG

ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-195

System Outline 1KD FTV 2KD FTV

2KD-FTVHigh Version

System Outline 1KD-FTV 2KD-FTVWithoutIntercooler

WithIntercooler

Swirl Control(See Page EG-216)

Based on the signals received from thesensors, the ECM controls the vacuum thatis directed to the actuator via the VSV, inorder to open and close the valve.

f*1 — — f*2

(See Page EG 216)Controls the valve opening in three stages:fully open, semi-open, and fully closed.

f*2 — — —

TurbochargerControl(See Page EG-218)

Based on the signals received from thesensors, the ECM controls the actuator inaccordance with the engine condition.

f — — —

EGR Control()

Based on the signals received from thesensors, the ECM determines the EGRvolume via EGR valve, EGR cooler bypassswitching valve and intake shutter valve(throttle valve) in accordance with theengine condition.

f*2 — — f*2

(See Page EG-223)Based on the signals received from thesensors, the ECM determines the EGRvolume via EGR valve and intake shuttervalve (throttle valve) in accordance with theengine condition.

f*1 f*3 f*3 f*1

Air ConditioningCut-off Control*4

By controlling the air conditioningcompressor ON or OFF in accordance withthe engine condition, drivability ismaintained.

f f f f

EngineImmobilizer*5

Prohibits fuel injection if an attempt is madeto start the engine with an invalid ignitionkey.

f f f f

Oil MaintenanceManagement

When the ECM determines engine oil andoil filter deterioration the engine oil change f*6 f*6

ManagementSystem(See Page EG-225)

oil filter deterioration, the engine oil changereminder light turns ON to inform the driver.

f*6 — — f*6

Diagnosis(See Page EG-227)

When the ECM detects a malfunction, itdiagnoses and memorizes the failed section.

f f f f

Fail-safe(See Page EG-227)

When the ECM detects a malfunction, itstops or controls the engine according to thedata already stored in the memory.

f f f f

*1: Except models compliant with EURO IV emission regulations*2: Models compliant with EURO IV emission regulations*3: Models for G.C.C. Countries and models compliant with EURO I, EURO III, EURO IV and Tier 1

emission regulations*4: Models with air conditioning system*5: Models with engine immobilizer system*6: Models for Europe

ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

00LEG75Y

INTAKE SHUTTER VALVEPOSITION SENSOR

CAMSHAFT POSITION SENSOR

CRANKSHAFT POSITION SENSOR

FUEL PRESSURE SENSOR

TURBO PRESSURE SENSOR

INTAKE AIR TEMP. SENSOR

WATER TEMP. SENSOR

ACCELERATOR PEDALPOSITION SENSOR

AIR FLOWMETER*1

FUEL TEMP. SENSOR

INTAKE AIR TEMP. SENSOR*2

EGR VALVEPOSITION SENSOR*3

VLU

G

NE

PCR1

PCR2*4

PIM

THA

THW

VPAVPA2

VG

THF

THIA

EGLS

ECM

#1

#2

#3

#4

INJFPRD*4

PCV

LUSL

EGR

EGRC

ECBV

GREL

IREL

SCV

SCV2

EDU

No. 1 INJECTOR

No. 2 INJECTOR

No. 3 INJECTOR

No. 4 INJECTOR

SUCTION CONTROL VALVE

INTAKE SHUTTER CONTROL

INTAKE SHUTTER VALVECONTROL MOTOR

EGR CONTROL*5

E-VRV(for EGR Valve Control)

VSV (for EGR Valve Close)*6

EGR COOLER BYPASSSWITCHING VALVE*7

GLOW PLUG CONTROL

GLOW PLUG RELAY

EDU RELAY

SWIRL CONTROL*6

VSV(for Swirl Control Valve)

VSV(for Swirl Control Valve)*4

(Continued)

EG-196

2. Construction

The configuration of the engine control system in the 1KD-FTV and 2KD-FTV engines is as shown in thefollowing chart.

*1: Models with 1KD-FTV engine, and 2KD-FTV engine compliant with EURO III & EURO IV emissionregulations (except models for Central & South America)

*2: Models with intercooler*3: Models with 1KD-FTV engine compliant with EURO IV emission regulations and 2KD-FTV engine

with EGR control*4: Models with 1KD-FTV engine compliant with EURO IV emission regulations*5: Models for G.C.C. Countries and models compliant with EURO I, EURO III, EURO IV and Tier 1

emission regulations*6: Models with 1KD-FTV engine, and 2KD-FTV engine compliant with EURO IV emission regulations*7: Models compliant with EURO IV emission regulations

EG


00LEG76IT

STOP LIGHT SWITCH

ALTERNATOR

NEUTRAL START SWITCH*1

CLUTCH SWITCH*3

IGNITION SWITCH

D Starting SignalD Ignition Signal

POWER HEATER AMPLIFIER*4

BATTERY

MAIN RELAY

TRANSPONDER KEY ECU*5

DLC3*12

ECT ECU*1

SKID CONTROL ECU*6

CAN (Powertrain Bus)

CAN (V Bus)

STP

ST1–

ALT

NSW

D*2

CLSW

STA

IGSW

VCT

VCH

BATT

MREL

+B

IMO

IMI

TCSIL

WFSETACH

ECM

VNTO

VNTI

ACT

AC1

HSW

PI

W

GIND

OILM

SPD

TACH

THWO

DM

CCS

TURBOCHARGER CONTROL*7

TURBOMOTORDRIVER

NOZZLE VANEOSITION SENSOR

DC MOTOR

A/C AMPLIFIER*8

Magnetic Clutch Actuation Signal

Idle-up Signal

POWER HEATER SWITCH*9

COMBINATION METER

CRUISE MAIN INDICATOR LIGHT*2

CHECK ENGINEWARNING LIGHT

GLOW INDICATOR LIGHT

ENGINE OIL CHANGEREMINDER LIGHT*10

Vehicle Speed Signal

TACHOMETER

Water Temp. Signal

Injection Volume Signal*11

CRUISE CONTROL MAIN SWITCH*2

DLC3*13

TC

TACH

EG-197

*1: Models with automatic transmission*2: Models with cruise control system*3: Models with manual transmission (with cruise control system)*4: Models with viscous type power heater*5: Models with engine immobilizer system*6: Models with VSC (Vehicle Stability Control)*7: Models with 1KD-FTV engine*8: Models with air conditioning system*9: Models with PTC heater*10:Models for Europe*11:Models with multi-information display*12:Exceptmodels 1KD-FTVengine (withA750Fautomatic transmission) and1KD-FTVengine compliant

with EURO IV emission regulations (with R151F manual transmission)*13:Models with 1KD-FTV engine (with A750F automatic transmission) or 1KD-FTV engine compliant

with EURO IV emission regulations (with R151F manual transmission)


00LEG77Y

Accelerator PedalPosition Sensor

Ignition Switch SignalStop Light Switch SignalAir Conditioning Signal*1


ECM

Glow Relay

Suction ControlValve

Fuel Temp.Sensor

Supply Pump

AtmosphericPressure Sensor

VSV(EGRValve Close)

Common-rail

EDURelay

Fuel PressureSensor

PressureDischarge Valve*2

E-VRVIntercooler

Intake AirTemp.Sensor EDU

Intake AirTemp. Sensor

VSV (for EGRCooler BypassSwitching Valve)

Intake ShutterValve ControlMotor

EGR ValvePosition Sensor

Turbo PressureSensor

Air Flow Meter

EGR CoolerActuator

D DC Motor*2D Nozzle VanePositionSensor*2

Turbo MotorDriver*2

Injector

VacuumPump

VSV

Glow Plug

CamshaftPosition Sensor

WaterTemp.Sensor

CrankshaftPosition Sensor

VSV(SwirlControlValve)*2

EG-198

3. Engine Control System Diagram

"Models Compliant with EURO IV Emission Regulations A

*1: Models with air conditioning system*2: Models with 1KD-FTV engine

EG


271EG134


Ignition Switch SignalStop Light Switch SignalAir Conditioning Signal*1


ECM

Glow Relay

SuctionControl Valve Fuel Temp.

Sensor

Supply Pump

AtmosphericPressure Sensor Pressure

Limiter

Common-rail

Fuel PressureSensor

Intake AirTemp. Sensor*2

VSV*4(EGR Valve Close)

E-VRV*7

Intake AirTemp.Sensor*5

EDURelay

Intercooler*5

EDU

Intake ShutterValve ControlMotor EGR Valve

Position Sensor*6

Turbo PressureSensorAir Flow Meter*2

Intake AirTemp. Sensor*3

D DC Motor*4D Nozzle VanePositionSensor*4

Turbo MotorDriver*4

Injector

Glow Plug

VSV*4(SwirlControlValve)

WaterTemp.Sensor



*3: Models without air flow meter*4: Models with 1KD-FTV engine*5: Models with intercooler*6: Models with 2KD-FTV engine (with EGR control)*7: Models with EGR control

EG-199

" Except Models Compliant with EURO IV Emission Regulations A

*1: Models with air conditioning system*2: Models with 1KD-FTV engine, and 2KD-FTV engine

compliant with EURO III & EURO IV emissionregulations (except models for Central & South America)


00LEG68Y

Air Flow Meter*1

Intake AirTemp. Sensor*2(Air Cleaner)

Glow Plug

Injector

Intake AirTemp. Sensor(Intercooler)*11

FuelPressureSensor

Intake Shutter ValvePosition Sensor

WaterTemp.Sensor

EGR ValvePosition Sensor*4

EGR Cooler*5 GlowIndicator Light

VSV*3(SwirlControlValve)


Pressure DischargeValve*6


Common-rail

Fuel Temp.Sensor

SCV

Supply Pump

Stop LightSwitch

DLC3


ECM

ECT ECU*8

LHDModels

Check EngineWarning Light

VSV (EGR Valve Close) *3

Engine Oil ChangeReminder Light*7

EDU

E-VRV*10Turbo Pressure Sensor

Turbo MotorDriver*9

*5: Models compliant with EURO IV emission regulations*6: Models with 1KD-FTV engine compliant with EURO IV

emission regulations*7: Models for Europe*8: Models with automatic transmission*9: Models with 1KD-FTV engine*10:Models with EGR control*11: Models with intercooler

EG-200

4. Layout of Main Components

*1: Models with 1KD-FTV engine, and 2KD-FTV enginecompliant with EURO III & EURO IV emissionregulations (except models for Central & South America)

*2: Models without air flow meter*3: Models with 1KD-FTV engine and 2KD-FTV engine

compliant with EURO IV emission regulations*4: Models with 1KD-FTV engine compliant with EURO

IV emission regulations and 2KD-FTV engine withEGR control

EG


5. Main Components of Engine Control System

General

The main components of the 1KD-FTV and 2KD-FTV engine control system are as follows:

Components Outline Quantity Function

ECM 32-bit CPU 1

The ECM effects overall control of theengine control system to suit the operatingconditions of the engine in accordancewith the signals provided by the sensors.

EDU DC/DC Converter 1

The EDU is used to drive the injector athigh speeds. The EDU has achievedhigh-speed driving under high fuelpressure conditions through the use of aDC/DC converter that provides a highvoltage, quick-charging system.


SemiconductorSilicon Chip Type

1 This sensor uses built-in semiconductorsto detect the intake manifold pressure.

Atmospheric PressureSensor

SemiconductorSilicon Chip Type

1This sensor, which is built into the ECM,uses semiconductors to detect theatmospheric pressure.

Fuel Pressure Sensor Semiconductor StrainGauge Type

1This sensor uses built-in semiconductorsto detect the internal pressure of thecommon-rail.

Crankshaft PositionSensor

Pick-up Coil Type(Rotor Teeth/36-2)

1 This sensor detects the engine speed andperforms the cylinder identification.

Camshaft PositionSensor

Pick-up Coil Type(Rotor Teeth/5)

1 This sensor performs the cylinderidentification.

Air Flow Meter*1 Hot-wire Type 1 This sensor uses a built-in hot-wire todirectly detect the intake air mass.

Intake AirTemperature Sensor(Built into Air FlowMeter)*1 Thermistor Type 1

This sensor, which is provided at the aircleaner outlet, detects the intake airtemperature by means of an internal

Intake AirTemperature Sensor(Air Cleaner Outlet)*2

Thermistor Type 1temperature by means of an internalthermistor.

Intake AirTemperature Sensor(Intercooler Outlet)*3

Thermistor Type 1This sensor, which is provided only on themodels with an intercooler, detects theintake air temperature past the intercooler.

Water TemperatureSensor

Thermistor Type 1This sensor detects the engine coolanttemperature by means of an internalthermistor.

Fuel TemperatureSensor

Thermistor Type 1This sensor detects the fuel temperature inthe supply pump by means of an internalthermistor.

(Continued)*1: Models with 1KD-FTVengine, and 2KD-FTVengine compliant with EUROIII &EUROIV emission

regulations (except models for Central & South America)*2: Models without air flow meter*3: Models with intercooler

ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-202

Components Outline Quantity Function

Intake Shutter ValvePosition Sensor

Non-contact Type 1This sensor detects the intake shutter valve(throttle valve) opening angle.


Non-contact Type 1

D This sensor detects the amount of pedaleffort applied to the accelerator pedal.

D The basic construction and operation ofthis sensor are the same as in the1TR-FE and 2TR-FE engines. Fordetails, see page EG-48.

EGR Valve PositionSensor*1

Contact Type 1This sensor detects the actual amount ofthe EGR valve opening.

SCV(Suction ControlValve)

Linear SolenoidValve

1

The SCV position is controlled by thesignals from the ECM, and a fuel volumethat suits the SCV position is drawn intothe pumping portion (plunger portion).

Injector8-hole Type*2

4

The injector contains a solenoid valve thatopens and closes to increase or decreasethe pressure in the control chamber ThisInjector

8 hole Type6-hole Type*3

4 the pressure in the control chamber. Thiscauses the nozzle needle to open and closethe valve, which results in fuel injection.

*1: Models with 1KD-FTV engine compliant with EURO IV emission regulations and 2KD-FTV engine(with EGR Control)

*2: Models with 1KD-FTV engine*3: Models with 2KD-FTV engine

ECM

D The 32-bit CPU of the ECM is used to increase the speed of signal processing.

D The ECM of the 2KD-FTV engine and 2KD-FTV High Version engine contain engine programs thatdiffer from each other. However, both engines share the same mechanical components.

D On the models with automatic transmission, the ECM maintains communication with a separate,independent ECT ECU through CAN (Controller Area Network). Thus, engine control is effected incoordination with ECT control.

EG


271EG136

Sensor Unit

(V)5

OutputVoltage

00 100 250

(kPa)

Intake Manifold Pressure

00LEG12

00MEG06

Detection Portion (V)

OutputVoltage

190(MPa)

Except Models with 1KD-FTV EngineCompliant with EURO IV Emission Regulations

Detection Portion

Fuel Pressure

(V)

OutputVoltage I

II

Fuel Pressure190

(MPa)

Models with 1KD-FTV EngineCompliant with EURO IV Emission Regulations

EG-203

Turbo Pressure Sensor

The turbo pressure sensor consists of a semiconductor which utilizes the characteristics of a silicon chipthat changes its electrical resistance when pressure is applied to it. The sensor converts the intake airpressure into an electrical signal, and sends it to the ECM in an amplified form.

Fuel Pressure Sensor

The fuel pressure sensor consists of a semiconductor which utilizes the characteristics of a silicon chip thatchanges its electrical resistance when pressure is applied to it. This sensor is mounted on the common-rail,outputs a signal that represents the fuel pressure in the common-rail to the ECM, in order to constantlyregulate the fuel at an optimal pressure.


224EG41


34 Pulses/360_ CA

Camshaft Position Sensor

5 Pulses/720_ CA

271EG138

5 Pulses/720 _CA

180_ CA 180_ CA 180_ CA

34 Pulses/360_ CA 34 Pulses/360_ CA

EG-204

Crankshaft and Camshaft Position Sensors

D The timing rotor of the crankshaft consists of 34 teeth, with 2 teeth missing. The crankshaft positionsensor outputs the crankshaft rotation signals every 10_, and themissing teeth are used to determine thetop-dead-center.

D To detect the camshaft position, a protrusion that is provided on the timing pulley is used to generate 5pulses for every 2 revolutions of the crankshaft.

" Sensor Output Waveforms A

EG


271EG83

271EG82

MagneticYoke

Hall IC

Intake Shutter Valve(Throttle Valve)

OutputVoltage

(V)

5

0

Turning Angle of Intake Shutter Valve ( _ )

100

EG-205

Intake Shutter Valve Position Sensor

The intake shutter valve position sensor is mounted on the intake shutter assembly. To detect the openingangle of the intake shutter valve (throttle valve), the intake shutter valve position sensor converts themagnetic flux density, that changes when the magnetic yoke (located on the same axis as the intake shuttervalve shaft) rotates around theHall IC, into electric signals to operate the intake shutter valve controlmotor.


00MEG43Y



Engine Speed

ECM

Calculation ofBasic InjectionVolume

ISC*1 Correction

Water Temp. Sensor

224EG46

ECM

Basic/MaximumInjection Volume(Map Data Inside of ECM)

Maximum InjectionVolume Correction

CrankshaftPosition SensorEngine Speed

Water Temp. Sensor

Fuel Temp. Sensor

D Intake AirTemp. Sensor

D Turbo PressureSensor

D Air Flow Meter*2

Intake Air Mass*2

EG-206

6. Fuel Injection Volume Control

The ECM calculates two types of values: the basic injection volume and the maximum injection volume.Then, the ECM compares the basic andmaximum injection volumes, and determines the smaller calculatedvalue to be the final injection volume.

" Basic Injection Volume A

"Maximum Injection Volume A

*1: Idle Speed Control*2: Models with air flow meter

EG


224EG48

ECM

Basic InjectionVolume

MaximumInjection Volume

Comparison

FuelPressure

Final EDU

Injector

201EG45


ECM

Basic Injection Timing

Injection Timing


Correction

Water Temp. Sensor

Intake Air Temp.Sensor


EDU Injector

Engine Speed

EG-207

" Final Injection Volume Decision A

7. Fuel Injection Timing Control

Fuel injection timing is controlled as shown below.


224EG50

ECM

+

Correction

Starter Signal

Water Temp.Sensor


Basic InjectionVolume

224EG51

ECM

Target InjectionTiming Correction

Starter Signal

Water Temp.Sensor


EG-208

8. During Starting Control

Injection Volume Control

The starting injection volume is determined by adjusting the basic injection volume in accordance with thestarter onsignals (on time) andcoolant temperature sensor signals andengine speed signal.When theengineis cold, the coolant temperature will be lower and the injection volume will be greater.

Injection Timing Control

To determine the starting injection timing, the target injection timing is corrected in accordance with thestarter signals, water temperature, and engine speed.When the water temperature is low, if the engine speed is high, the injection timing is advanced.

EG


233EG14

ECM

Comparison

Actual Engine Speed

Injection VolumeCorrection

AcceleratorPedal PositionSensor

Water Temp.Sensor

Vehicle SpeedSensor

Starter Signal

A/C Signal*

Idle-up Signal


Target SpeedCalculation

EG-209

9. Idle Speed Control

ISC correction is controlled as shown below.

*: Models with air conditioning system


04ZEG025Y



ECM

Calculation ofTarget InjectionPressure

Supply Pump

Feed Pump SCV

ControlSuctionVolume

Plunger

Fuel PumpingFuel PressureSensor

Common-rail Pressure DischargeValve

Fuel Injection Injector EDU

Fuel Tank

EG-210

10. Fuel Pressure Control

General

1) Models with 1KD-FTV Engine Compliant with EURO IV Emission Regulations

The ECM calculates the target injection pressure (32 – 160 MPa) based on the signals from theaccelerator pedal position sensor and the crankshaft position sensor.To control fuel pressure, signals sent to the SCV (Suction Control Valve) of the supply pump regulatethe suction volume, and signals sent to pressure discharge valve of the common-rail regulate thedischarge volume, so that the pressure detected by the fuel pressure sensor matches the target injectionpressure.

EG


002CV36Y



ECM

Calculation ofTarget InjectionPressure

Supply Pump

Feed Pump SCVControlsSuctionVolume

Plunger

Fuel PumpingFuel PressureSensor

Common-rail Pressure Limiter

Fuel Injection Injector EDU

Fuel Tank

EG-211

2) Except Models with 1KD-FTV Engine Compliant with EURO IV Emission Regulations

The ECM calculates the target injection pressure* based on the signals from the accelerator pedalposition sensor and the crankshaft position sensor.To control fuel pressure, signals sent to the SCV (Suction Control Valve) of the supply pump regulatethe suction volume, so that the pressure detected by the fuel pressure sensor matches the target injectionpressure.

*: Target injection pressure

1KD-FTV engine 32 – 160 MPa

2KD-FTV engine 30 – 160 MPa


00MEG34Y

Plunger TDC

Fuel Pumping Mass

Plunger BDCPumpingStarting Point

CamStroke

SCV

Small SuctionArea

(a) (b) (c)

EG-212

System Operation

1) General

The ECM controls the opening of the SCV in order to regulate the volume of fuel that is pumped by thesupply pump to the common-rail. Consequently, the fuel pressure in the common-rail is controlled to thetarget injection pressure.

2) SCV Opening Small

(a) When the opening of the SCV is small, the fuel suction area is kept small, which decreases thetransferable fuel quantity.

(b) When the plunger strokes fully, however, the suction volume becomes small due to the small suctionarea. Therefore, the difference of the volume between the geometry volume and the suction volumeis in vacuum condition.

(c) Pumping will start when the fuel pressure has become higher than the common-rail pressure.

EG


00MEG35Y

CamStroke

Fuel Pumping MassPumpingStarting Point

Large SuctionArea

SCV

(a) (b) (c)

EG-213

3) SCV Opening Large

(a) When the opening of the SCV is large, the fuel suction area is kept large, which increases thetransferable fuel quantity.

(b) If the plunger strokes fully, the suction volume will increase because the suction area is large.

(c) Pumping will start at the time when the fuel pressure has become higher than the common-railpressure.


168EG23

State Pilot Injection Ordinary Injection

Fuel Injection

CombustionPressure

Pilot Injection Main Injection

201EG45


ECM

Basic Pilot Injection(Volume, Timing, Interval)

Pilot Injection(Volume, Timing, Interval)

Correction

Intake Air Temp.Sensor

Water Temp. Sensor


EDU Injector

Engine Speed


EG-214

11. Pilot Injection Control

D Pilot injection is a method that provides an auxiliary fuel injection before the main fuel injection takesplace. The purpose of pilot injection is to gently start the combustion of the fuel of the main injection inorder to reduce combustion noise.

D During pilot injection, the pilot injection volume, timing, and interval (between pilot injection and maininjection) are controlled as shown below.

EG


271EG140

Intake ShutterValve PositionSensor

Intake Shutter ValveControl Motor

Intake ShutterValve

Engine Speed

Vehicle Speed

Water Temp.

Intake Air Temp.Accelerator PedalPositionIntake Air Pressure

Ignition Switch

ECM

EG-215

12. Intake Shutter Control

The opening of the intake shutter valve (throttle valve) is controlled by the ECM in accordance with theengine conditions.As a result, the noise that is generated during idling and deceleration, as well as the noise and vibration thatare generated when the engine is stopped, have been reduced and this control makes it possible to recirculatethe exhaust gas in accordance with the driving conditions.


271EG90

Combustion Chamber

Intake Port

Swirl ControlValve

Actuator

VacuumPump

VSV

Accelerator Pedal PositionEngine Speed

ECM

EG-216

13. Swirl Control

General

D On the models with 1KD-FTV engine and 2KD-FTV High Version engine compliant with EURO IVemission regulations, a swirl control is used.

D On the models with 1KD-FTV engine (except models compliant with EURO IV emission regulations)and 2KD-FTV High Version engine, a swirl control valve with 2-stage control is used.On the models with 1KD-FTV engine compliant with EURO IV emission regulations, a swirl controlvalve with 3-stage control is used.

Operation

1) General

The ECM determines the swirl control valve position based on the engine conditions (engine speed andaccelerator pedal effort). Then, it switches the vacuum applied to the actuator diaphragm via the VSV,in order to open and close the swirl control valve.

2) Except Models with 1KD-FTV Engine Compliant with EURO IV Emission Regulations

D On a cold engine, the ECM fully closes the swirl control valve to reduce the amount of white smokeemissions.

D In the low engine speed range, the ECM closes the swirl control valve to strengthen the swirl in thecombustion chamber, thus promoting the mixture of fuel and air and stabilizing combustion.

D When the engine speed increases to the low or middle-speed range, the ECM fully opens the swirlcontrol valve.

EG


041EG07

Combustion Chamber

Actuator

SwirlControlValve

IntakePort

VacuumPump

VSV

VSV

AcceleratorPedal Position

Engine Speed

ECM

EG-217

3) Models with 1KD-FTV Engine Compliant with EURO IV Emission Regulations

D On a cold engine, the ECM fully closes the swirl control valve to reduce the amount of white smokeemissions.

D In the low engine speed range, the ECM closes the swirl control valve to strengthen the swirl in thecombustion chamber, thus promoting the mixture of fuel and air and stabilizing combustion.

D In the middle engine speed range, the ECM opens the swirl control valve to the semi-open position.

D In the high engine speed range, the ECM fully opens the swirl control valve.


271EG141

DC Motor

Nozzle VanePositionSensor

Actual NozzleVane Position

Nozzle VanePosition Control

Turbo MotorDriver


Target Nozzle Vane Position Signal

Turbocharger Control Status

AtmosphericPressureSensor

ECM

CrankshaftPositionSensor

Injector

Water Temp.Sensor

Intake AirTemp.Sensor

EG-218

14. Turbo Charger Control

General

D On the models with 1KD-FTV engine, a turbocharger control system is used.

D TheECMcontrols the nozzle vane position using the turbomotor driver, in order to obtain the calculatedtarget turbo pressure appropriate to the engine operating conditions.

D The ECMcalculates the optimal nozzle vane position in accordance with the driving conditions (enginespeed, injection volume, atmospheric pressure, and water temperature etc), and sends a target nozzlevane position signal to the turbo motor driver. The turbo motor driver controls the nozzle vane positionin accordance with this signal and the actual nozzle vane position signal provided by the nozzle vaneposition sensor.

EG


271EG142

TurbineWheel

Driven Arm

Drive Arm

Nozzle Vane

DC Motor

Nozzle VanePosition Sensor

Linkage

Full-close Stopper

Unison Ring

EG-219

Construction

1) General

Avariable nozzle vane device is established on the turbine (exhaust) side, which consists of a DCmotor,nozzle vane position sensor, linkage, drive arm, unison ring, driven arms and nozzle vanes.


Service Tip

D To control the nozzle vane position, the turbo motor driver renders the contact position of thelinkagewith the full-close stopper (thus fully closing the nozzle vane) as the zero point for thenozzle vane position sensor.

D If the turbocharger has been reinstalled or replaced, turn the ignition switch from ON to OFFonce, and make sure that the linkage comes in contact with the full-close stopper.

D The full-close stopper position, which is adjusted at the factory at the time of shipment, is notserviceable in the field. For this reason, if the linkage does not come in contact with thefull-close stopper during an inspection, the turbocharger assembly must be replaced.Neverattempt to loosenor tighten the locknut of the full-close stopper because itwill adverselyaffect the performance of the engine.

D For details, refer to the Hilux Repair Manual.

271EG143

Linkage

Open

Close

Full-closeStopper

Lock Nut

EG-220

EG


271EG148

Hall IC

Magnetic Yoke Sensor Vane

Full Closed Full Open

Sensor Vane271EG147

(V)

4.5

0.5

Full Closed

Nozzle Vane Position

Full Open

OutputVoltage

00LEG79IT


Magnetic Yoke

Sensor Vane

HallIC

VCX1

VSX1

E2X1

TurboMotorDriver


Sensor Vane

Magnetic YokeVNVC

VTA1

VNE2

HallIC

HallIC

TurboMotorDriver

VCS

VTA2

E2S

Models Compliant with EURO IVEmission Regulations

Except Models Compliant withEURO IV Emission Regulations

EG-221

2) Nozzle Vane Position Sensor

The nozzle vane position sensor consists of a Hall IC and amagnetic yoke that rotates in unison with themovement of the linkage that actuates the nozzle vane. The nozzle vane position sensor converts thechanges in the magnetic flux that are caused by the rotation of the DCmotor (hence, the rotation of themagnetic yoke) into electric signals, and outputs them to the turbo motor driver. The turbo motor driverdetermines the actual nozzle vane position from the electric signals in order to calculate the target nozzlevane position.

" System Diagram A


271EG144

Nozzle Vane

Gas Flow

Plate

Linkage

DC Motor

Drive ArmDriven Arm

Unison Ring

Linkage

Driven ArmCutout Portion

Fulcrum

271EG145

EG-222

Operation

1) At Engine Low Speed Range

When the engine is running in a lowspeed range, theDCmotor presses down the linkage by a signal fromthe turbo motor driver. The tip of the linkage rotates the unison ring counterclockwise through a drivearm.The unison ring contains a driven arm,which is placed through the cutout portion of the unison ring. Thisdriven arm also moves in the direction of the rotation of the unison ring. The fulcrum of the driven armis an axis that is integrated with the nozzle vane behind the plate. When the driven arm movescounterclockwise, the nozzle vane moves toward the closing direction. This results in increasing thevelocity of the exhaust gas flowing to the turbine, as well as the speed of the turbine. As a result, torqueis improved when the engine is running at low speeds.

2) At Engine Medium-to-high Speed Range

When the engine is running in a medium-to-high speed range, the DC motor pulls up the linkage by asignal from the turbo motor driver.With this, the driven armmoves clockwise and this opens the nozzlevane and holds the specified supercharging pressure. Thus, lowering the back pressure and improvingthe output and fuel consumption.

EG


15. EGR Control

General

D On the models for G.C.C. Countries andmodels compliant with EURO I, EURO III, EURO IV and Tier1 emission regulations, an EGR control is used.

D This system is designed to reduce and control NOx formation due to a slight reduction of the peaktemperature in the engine combustion chamber, which is accomplished by introducing a small amountof inert gas into intake manifold.

D The table below lists the differences between the EGR system on the 1KD-FTVand 2KD-FTVengines.

EngineEGR Valve

Position SensorVSV

(for EGR Valve Close)

EGR Cooler BypassSwitching Valve and VSV

(for EGR CoolerBypass Switching Valve)

1KD-FTV

Compliantwith EURO IV

f f f1KD FTV

Others — f —

2KD-FTV

Compliantwith EURO IV

f f f2KD FTV

Others f — —

Operation

D By sensing the engine driving conditions and actual amount of EGR valve opening*1, the ECMelectrically operates the E-VRV (for EGR valve control) and VSV (for EGR valve close)*2, whichcontrols the magnitude of vacuum introduced into diaphragm of EGR valve and intake shutter valve(throttle valve) opening position with intake shutter valve control motor and the amount of recirculatingexhaust gas is regulated. EGR valve opening lift is controlled by modulated negative pressure.

D On the models with VSV (for EGR valve close), the VSV (for EGR valve close) is activated when theEGRcontrol is stopped, in order to introduce the atmospheric pressure to the EGRvalve diaphragm andimprove EGR valve closure response to maintain driveability.

D On the models compliant with EURO IV emission regulations, the ECM switches the bypass passageof the EGR cooler via the VSV (for EGR cooler bypass switching valve) in order to optimize thetemperature of the EGR gas and clean exhaust gases.

*1: Models with EGR valve position sensor*2: Models with VSV (for EGR valve close)


041EG09

03XEG18Y

IntakeShutterValvePositionSensor

IntakeManifold

IntakeShutterValve

Intake Shutter Valve Control Motor

EGR Valve Position Sensor*1

VacuumDamper

EGRValve

Engine

Exhaust Manifold

VSV*2(for EGR Valve Close)

E-VRV(for EGR Valve Control)

VacuumPump

ECM



Accelerator PedalPosition SensorWater Temp.SensorTurbo PressureSensorIntake AirTemp. Sensor

Air FlowMeter*3

Models Compliant with EURO IV Emission Regulations

IntakeShutterValvePositionSensor

IntakeManifold

IntakeShutterValve

Engine

IntakeShutterValveControlMotor

EGR Valve Position Sensor

VacuumDamper VSV (for EGR

Valve Close)

EGRValve

EGR CoolerBypassSwitchingValve

EGR Cooler

Exhaust Manifold Bypass Passage

VSV (for EGR Cooler BypassSwitching Valve)

E-VRV(for EGRValve Control)

VacuumPump

ECM


Crankshaft Position Sensor

Accelerator Pedal PositionSensor

Water Temperature Sensor


Intake Air TemperatureSensorAir Flow Meter

ExceptModels Compliant with EUROIVEmissionRegulations

EG-224

*1: Models with 2KD-FTV engine*2: Models with 1KD-FTV engine*3: Models with air flow meter

EG


291EG34

ECMD Engine SpeedD Injection VolumeD Injection TimingD Intake Air Mass

SootVolume Meter

ECU

Combination Meter

ODO/TRIPSwitch

VehicleSpeed Sensor

Engine OilChange ReminderLight

291EG18

Combination MeterD Engine Oil Change Reminder LightD ODO/TRIP Switch

ECM

EG-225

16. Oil Maintenance Management System

General

D On the models for Europe, an oil maintenance management system is used. This system determines thedeterioration conditions of the engine oil and illuminates an engine oil change reminder light to informthe driver when the engine oil and the oil filter must be changed. Accordingly, the maintenance intervals(30000 kmmaximum) that correspond to the actual deterioration conditions of the engine oil have beenrealized.

D This system indirectly determines the deterioration of the engine oil based on the information providedby the ECM.

System Diagram

Layout of Components


SootContaminationVolume

224EG36224EG35

Large

Small

Largez Air-fuel Ratio! Small

Relationship to Air-fuel Ratio

SootContaminationVolume

Large

Small

Earlyz Injection Ending Timing! Late

Relationship to Injection Ending Timing

291EG26224EG37

Normal During Soot pulse transmission

Soot Pulse Signal(1 Count)

NOTICE

This system does not determine the deterioration of the engine oil based on the elapsed time.Even if the engine oil change reminder light does not illuminate, the engine oil and oil filter shouldbe changed at 2-year intervals at the maximum.

EG-226

System Operation

D This system determines the deterioration of the engine oil in accordance with the soot volume in theengine oil. The ECM calculates the soot volume in the engine oil in accordance with the engine speed,injection timing, injection volume, and air-fuel ratio. The ECM converts the soot volume into pulsesignals and transmits the signals to the meter ECU. The meter ECU counts the pulse signals as the sootvolume, and blinks an engine oil change reminder light when the cumulative value gets closer to apredetermined value, and illuminates the reminder light when the cumulative value reaches thepredetermined value. Thus, this system informs the driver that the engine oil and the oil filter must bechanged.

" Soot Generation Conditions A

" Soot Pulse Signal A

D In addition to controlling the illumination of the engine oil change reminder light by calculating the sootvolume, the ECM blinks the reminder light when the vehicle travel distance reaches 25000 km, andilluminates it when the travel distance reaches 30000 km. Thus, this function enhances the reliability ofthe system.

Counter Reset

For details about the method to reset the engine oil change reminder light, see page BE-14.

EG


Service Tip

To clear the DTC that is stored in the ECM, use an intelligent tester II or disconnect the batteryterminal or remove the EFI fuse for 1 minute or longer.

EG-227

17. Diagnosis

D The diagnosis system of the 1KD-FTV and 2KD-FTV engine uses the EURO-OBD (Europe On-BoardDiagnosis) that complies with European regulations.

D When theECMdetects amalfunction, itmakes adiagnosis andmemorizes the failed section.Furthermore,the check engine warning light in the combination meter illuminates to inform the driver.

D The 2-digit DTCs (Diagnostic Trouble Codes) can be accessed by connecting the SST (09843-18040) tothe DLC3 terminals TC and CG, and reading the blinking of the check engine warning light.

D By using the intelligent tester II, the 5-digit DTCs and ECMdata can be read out.Moreover, the ACTIVETEST can be used to drive the actuator by means of the intelligent tester II.

D The ECM will also store the DTCs (Diagnostic Trouble Codes) of the malfunctions.

D The DTCs can be accessed by the use of the intelligent tester II.

D All the DTCs have been made to correspond to the SAE controlled codes.

18. Fail-safe

When amalfunction is detected by any of the sensors, there is a possibility of an engine or othermalfunctionoccurring if the ECM continues to control the engine control system in the normal way. To prevent such aproblem, the fail-safe function of the ECM either relies on the data stored in memory to allow the enginecontrol system to continue operating, or stops the engine if a hazard is anticipated. For details, refer to theHilux Repair Manual.

diesel

Documents

f f f fcontinued

f egr controlbased

kdftv engineseg

egr valve

theengine condition

ecm optimallycontrols

turbochargercontrolsee

fuel injection volume