EG-194

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

JENGINE CONTROL SYSTEM

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

Fuel Injection
Volume Control
(See Page EG-206)
Fuel Injection
Timing Control
(See Page EG-207)
During Starting
Control
(See Page EG-208)
Idle Speed Control
(See Page EG-209)

Fuel Pressure
Control
(See Page EG-210)

Pilot Injection
Control
(See Page EG-214)

Outline
Based on the signals received from the
sensors, the ECM determines the fuel
injection volume in accordance with the
engine condition.
Based on the signals received from the
sensors, the ECM determines the fuel
injection timing in accordance with the
engine condition.
To facilitate startability, the ECM optimally
controls the injection volume and injection
timing during starting.
The ECM determines the idle speed in
accordance with the engine condition, and
controls the fuel injection volume in order to
maintain the target idle speed.
Based on the signals received from the
sensors, the ECM controls fuel pressure
using the SCV (Suction Control Valve) and
pressure discharge valve according to
engine operating conditions.
Based on the signals received from the
sensors, the ECM controls fuel pressure
using the SCV according to engine
conditions.
Based on the signals received from the
sensors, the ECM determines pilot injection
volume/timing, and interval (between pilot
injection and main injection) in accordance
with the engine condition.

2KD-FTV
High Version
Without
With
Intercooler Intercooler

1KD FTV
1KD-FTV

2KD FTV
2KD-FTV

f*1

f*2

Glow Plug Control

Controls the length of time when the current

is applied to the glow plugs, in accordance
with the coolant temperature.

Intake Shutter
Control
(See Page EG-215)

D Controls the intake shutter valve (throttle

valve) opening angle in accordance with
the engine condition.
D Fully closes the intake shutter valve
(throttle valve) in order to reduce the
vibration when the engine is stopped.

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

EG-195

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

System

Outline

1KD FTV
1KD-FTV

2KD FTV
2KD-FTV

Based on the signals received from the

sensors, the ECM controls the vacuum that
is directed to the actuator via the VSV, in
order to open and close the valve.

f*1

Controls the valve opening in three stages:

fully open, semi-open, and fully closed.

2KD-FTV
High Version
Without
Intercooler

With
Intercooler

f*2

f*2

Based on the signals received from the

sensors, the ECM controls the actuator in
accordance with the engine condition.

Based on the signals received from the

sensors, the ECM determines the EGR
volume via EGR valve, EGR cooler bypass
switching valve and intake shutter valve
(throttle valve) in accordance with the
engine condition.

f*2

f*2

Based on the signals received from the

sensors, the ECM determines the EGR
volume via EGR valve and intake shutter
valve (throttle valve) in accordance with the
engine condition.

f*1

f*3

f*3

f*1

Air Conditioning
Cut-off Control*4

By controlling the air conditioning

compressor ON or OFF in accordance with
the engine condition, drivability is
maintained.

Engine
Immobilizer*5

Prohibits fuel injection if an attempt is made

to start the engine with an invalid ignition
key.

Oil Maintenance
Management
System
(See Page EG-225)

When the ECM determines engine oil and

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

f*6

f*6

Diagnosis
(See Page EG-227)

When the ECM detects a malfunction, it

diagnoses and memorizes the failed section.

Fail-safe
(See Page EG-227)

When the ECM detects a malfunction, it

stops or controls the engine according to the
data already stored in the memory.

Swirl Control
EG-216)
(See Page EG
216)

Turbocharger
Control
(See Page EG-218)

EGR Control
() Page EG-223)
(See

*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

EG

EG-196

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

2. Construction
The configuration of the engine control system in the 1KD-FTV and 2KD-FTV engines is as shown in the
following chart.
INTAKE SHUTTER VALVE
POSITION SENSOR

#1

VLU

#2
#3

CAMSHAFT POSITION SENSOR

CRANKSHAFT POSITION SENSOR

FUEL PRESSURE SENSOR

#4

E
D
U

No. 2 INJECTOR
No. 3 INJECTOR
No. 4 INJECTOR

INJF
PRD*4

NE

PCV
PCR1

SUCTION CONTROL VALVE

INTAKE SHUTTER CONTROL

PCR2*4
LUSL

TURBO PRESSURE SENSOR

No. 1 INJECTOR

PIM

INTAKE SHUTTER VALVE

CONTROL MOTOR

EGR CONTROL*5
INTAKE AIR TEMP. SENSOR

THA

WATER TEMP. SENSOR

THW

ACCELERATOR PEDAL
POSITION SENSOR

ECM

EGR
EGRC

VSV (for EGR Valve Close)*6

ECBV

EGR COOLER BYPASS

SWITCHING VALVE*7

VPA
VPA2

AIR FLOW METER*1

VG

FUEL TEMP. SENSOR

THF

INTAKE AIR TEMP. SENSOR*2

THIA

EGR VALVE
POSITION SENSOR*3

EGLS

E-VRV
(for EGR Valve Control)

GLOW PLUG CONTROL

GREL
IREL

GLOW PLUG RELAY

EDU RELAY
SWIRL CONTROL*6

SCV

VSV
(for Swirl Control Valve)

SCV2

VSV
(for Swirl Control Valve)*4
(Continued)
00LEG75Y

*1: Models with 1KD-FTV engine, and 2KD-FTV engine compliant with EURO III & EURO IV emission
regulations (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-197

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

STOP LIGHT SWITCH

STP

TURBOCHARGER CONTROL*7

ST1
VNTO
ALT

ALTERNATOR

VNTI

NEUTRAL START SWITCH*1

NSW

CLUTCH SWITCH*3

CLSW

NOZZLE VANE
OSITION SENSOR

D*2

DC MOTOR

IGNITION SWITCH
D Starting Signal
D Ignition Signal

A/C AMPLIFIER*8

STA
ACT

IGSW

AC1

POWER HEATER AMPLIFIER*4

VCT
VCH

TURBO MOTOR
DRIVER

ECM

HSW

Magnetic Clutch Actuation Signal

Idle-up Signal
POWER HEATER SWITCH*9

BATT

BATTERY

MREL

MAIN RELAY

COMBINATION METER
PI

+B
IMO

TRANSPONDER KEY

ECU*5
IMI
TC
SIL
WFSE
TACH

DLC3*12

GIND

OILM
SPD

TC
TACH

DLC3*13

TACH
THWO

CAN (V Bus)
SKID CONTROL ECU*6

DM

CRUISE MAIN INDICATOR LIGHT*2

CHECK ENGINE
WARNING LIGHT
GLOW INDICATOR LIGHT

ENGINE OIL CHANGE

REMINDER LIGHT*10
Vehicle Speed Signal
TACHOMETER
Water Temp. Signal
Injection Volume Signal*11

CAN (Powertrain Bus)

ECT ECU*1

CCS

CRUISE CONTROL MAIN SWITCH*2

00LEG76IT

*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:Except models 1KD-FTV engine (with A750F automatic transmission) and 1KD-FTV engine 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)

EG

EG-198

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

3. Engine Control System Diagram

"

Models Compliant with EURO IV Emission Regulations A

Accelerator Pedal
Position Sensor

Ignition Switch Signal

Stop Light Switch Signal
Air Conditioning Signal*1
Vehicle Speed Signal

Glow Relay
Suction Control
Valve

ECM

Fuel Temp.
Sensor
Supply Pump

VSV
(EGR
Valve Close)

Atmospheric
Pressure Sensor

EDU
Relay
Common-rail
Fuel Pressure
Sensor

E-VRV
Pressure
Discharge Valve*2 Intercooler
VSV (for EGR
Cooler Bypass
Switching Valve)

Intake Air
Temp. Sensor

Intake Air
Temp.
Sensor

EDU
Intake Shutter
Valve Control
Motor

EGR Valve
Position Sensor
Turbo Pressure
Sensor

Air Flow Meter

Actuator

EGR Cooler
D DC Motor*2
D Nozzle Vane
Position
Sensor*2

Vacuum
Pump

VSV

Turbo Motor
Driver*2

Injector
Glow Plug

Water
Temp.
Sensor

VSV
(Swirl
Control
Valve)*2

Camshaft
Position Sensor
Crankshaft
Position Sensor

*1: Models with air conditioning system

*2: Models with 1KD-FTV engine

00LEG77Y

EG-199

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

"

Except Models Compliant with EURO IV Emission Regulations A

Accelerator Pedal
Position Sensor

Ignition Switch Signal

Stop Light Switch Signal
Air Conditioning Signal*1
Vehicle Speed Signal

Glow Relay
Suction
Control Valve

Fuel Temp.
Sensor

ECM

Supply Pump

Atmospheric
Pressure Sensor

Pressure
Limiter
VSV*4
(EGR Valve Close)

Common-rail

Intake Air
Temp.
Sensor*5

Intake Air
Fuel Pressure Temp. Sensor*2
Sensor

Intercooler*5

E-VRV*7

EDU
Relay
EDU
Intake Shutter
Valve Control
EGR Valve
Motor

Position Sensor*6
Turbo Pressure
Sensor

Air Flow Meter*2

Intake Air
Temp. Sensor*3
D DC Motor*4
D Nozzle Vane
Position
Sensor*4

Glow Plug

Turbo Motor
Driver*4

VSV*4
(Swirl
Control
Valve)

Injector
Water
Temp.
Sensor

Camshaft
Position Sensor
Crankshaft
Position Sensor

*1: Models with air conditioning system

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

*3:
*4:
*5:
*6:
*7:

Models without air flow meter

Models with 1KD-FTV engine
Models with intercooler
Models with 2KD-FTV engine (with EGR control)
Models with EGR control

271EG134

EG

EG-200

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

4. Layout of Main Components

Turbo Pressure Sensor

E-VRV*10

EDU
Air Flow Meter*1
Intake Air
Temp. Sensor*2
(Air Cleaner)
Glow Plug Intake Air

Temp. Sensor
(Intercooler)* 11

Injector

Intake Shutter Valve

Position Sensor

Fuel
Pressure
Sensor

EGR Valve
Position Sensor*4

Water
Temp.
Sensor

EGR Cooler*5

VSV (EGR Valve Close) *3

Check Engine
Warning Light

Glow
Indicator Light

VSV*3
(Swirl
Control
Valve)
Engine Oil Change
Reminder Light*7
Pressure Discharge
Valve*6

Crankshaft
Position Sensor

Common-rail

Camshaft
Position Sensor

Fuel Temp.
Sensor
Stop Light
Switch
DLC3

SCV

Accelerator Pedal
Position Sensor
Supply Pump

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

compliant with EURO III & EURO IV emission
regulations (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 with
EGR control

ECM
ECT ECU*8
LHD Models

Turbo Motor
Driver*9 00LEG68Y

*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

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

EG-201

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
ECM

Outline

Quantity

32-bit CPU

EDU

DC/DC Converter

Turbo Pressure
Sensor

Semiconductor
Silicon Chip Type

Atmospheric Pressure
Sensor

Semiconductor
Silicon Chip Type

Fuel Pressure Sensor

Semiconductor Strain
Gauge Type

Crankshaft Position
Sensor
Camshaft Position
Sensor

Pick-up Coil Type

(Rotor Teeth/36-2)
Pick-up Coil Type
(Rotor Teeth/5)

Air Flow Meter*1

Intake Air
Temperature Sensor
(Built into Air Flow
Meter)*1
Intake Air
Temperature Sensor
(Air Cleaner Outlet)*2
Intake Air
Temperature Sensor
(Intercooler Outlet)*3

Hot-wire Type

1
1
1

Thermistor Type

Thermistor Type

Water Temperature
Sensor

Thermistor Type

Fuel Temperature
Sensor

Thermistor Type

Function
The ECM effects overall control of the
engine control system to suit the operating
conditions of the engine in accordance
with the signals provided by the sensors.
The EDU is used to drive the injector at
high speeds. The EDU has achieved
high-speed driving under high fuel
pressure conditions through the use of a
DC/DC converter that provides a high
voltage, quick-charging system.
This sensor uses built-in semiconductors
to detect the intake manifold pressure.
This sensor, which is built into the ECM,
uses semiconductors to detect the
atmospheric pressure.
This sensor uses built-in semiconductors
to detect the internal pressure of the
common-rail.
This sensor detects the engine speed and
performs the cylinder identification.
This sensor performs the cylinder
identification.
This sensor uses a built-in hot-wire to
directly detect the intake air mass.
This sensor, which is provided at the air
cleaner outlet, detects the intake air
temperature by means of an internal
thermistor.
This sensor, which is provided only on the
models with an intercooler, detects the
intake air temperature past the intercooler.
This sensor detects the engine coolant
temperature by means of an internal
thermistor.
This sensor detects the fuel temperature in
the supply pump by means of an internal
thermistor.

(Continued)
*1: Models with 1KD-FTV engine, and 2KD-FTV engine compliant with EURO III & EURO IV emission
regulations (except models for Central & South America)
*2: Models without air flow meter
*3: Models with intercooler

EG

EG-202

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Components

Intake Shutter Valve

Position Sensor

Accelerator Pedal
Position Sensor

EGR Valve Position

Sensor*1
SCV
(Suction Control
Valve)

Injector

Outline

Quantity

Function

Non-contact Type

This sensor detects the intake shutter valve

(throttle valve) opening angle.

Non-contact Type

D This sensor detects the amount of pedal

effort applied to the accelerator pedal.
D The basic construction and operation of
this sensor are the same as in the
1TR-FE and 2TR-FE engines. For
details, see page EG-48.

Contact Type

This sensor detects the actual amount of

the EGR valve opening.

The SCV position is controlled by the

signals from the ECM, and a fuel volume
that suits the SCV position is drawn into
the pumping portion (plunger portion).

The injector contains a solenoid valve that

opens and closes to increase or decrease
the pressure in the control chamber.
chamber This
causes the nozzle needle to open and close
the valve, which results in fuel injection.

Linear Solenoid
Valve

8 hole Type*
8-hole
Type 2
6-hole Type*3

*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 that
differ 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 in
coordination with ECT control.

EG-203

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Turbo Pressure Sensor

The turbo pressure sensor consists of a semiconductor which utilizes the characteristics of a silicon chip
that changes its electrical resistance when pressure is applied to it. The sensor converts the intake air
pressure into an electrical signal, and sends it to the ECM in an amplified form.
Sensor Unit
(V)
5
Output
Voltage

EG
0

0
100
250
Intake Manifold Pressure

(kPa)
271EG136

Fuel Pressure Sensor

The fuel pressure sensor consists of a semiconductor which utilizes the characteristics of a silicon chip that
changes 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 constantly
regulate the fuel at an optimal pressure.
(V)

Detection Portion
Output
Voltage

Fuel Pressure 190

(MPa)
00MEG06

Except Models with 1KD-FTV Engine

Compliant with EURO IV Emission Regulations
(V)

Detection Portion
Output
Voltage

I
II

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

190

(MPa)
00LEG12

EG-204

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Crankshaft and Camshaft Position Sensors

D The timing rotor of the crankshaft consists of 34 teeth, with 2 teeth missing. The crankshaft position
sensor outputs the crankshaft rotation signals every 10_, and the missing teeth are used to determine the
top-dead-center.
D To detect the camshaft position, a protrusion that is provided on the timing pulley is used to generate 5
pulses for every 2 revolutions of the crankshaft.

Camshaft Position Sensor

Crankshaft
Position Sensor

5 Pulses/720_ CA

34 Pulses/360_ CA

224EG41

"

Sensor Output Waveforms A

5 Pulses/720 _CA
180_ CA

180_ CA

34 Pulses/360_ CA

180_ CA

34 Pulses/360_ CA
271EG138

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

EG-205

Intake Shutter Valve Position Sensor

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

EG

Output
Voltage
(V)

Magnetic
Yoke

271EG82

Intake Shutter Valve

(Throttle Valve)

100
Turning Angle of Intake Shutter Valve ( _ )
271EG83

EG-206

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

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 and maximum injection volumes, and determines the smaller calculated
value to be the final injection volume.
"

Basic Injection Volume A

Accelerator Pedal
Position Sensor

Crankshaft
Position Sensor

Engine Speed

ECM

Calculation of
Basic Injection
Volume

Water Temp. Sensor

ISC*1 Correction
00MEG43Y

"

Maximum Injection Volume A

ECM
Basic/Maximum
Injection Volume
(Map Data Inside of ECM)

Crankshaft
Position Sensor
Engine Speed
Water Temp. Sensor

Maximum Injection
Volume Correction

Fuel Temp. Sensor

D Intake Air
Temp. Sensor
D Turbo Pressure
Sensor
D Air Flow Meter*2

Intake Air Mass*2

*1: Idle Speed Control

*2: Models with air flow meter

224EG46

EG-207

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

"

Final Injection Volume Decision A

ECM
Basic Injection
Volume

Fuel
Pressure

Comparison

Final

EDU

Maximum
Injection Volume

EG
Injector
224EG48

7. Fuel Injection Timing Control

Fuel injection timing is controlled as shown below.

Accelerator Pedal
Position Sensor

Crankshaft
Position Sensor
Engine Speed

ECM
Basic Injection Timing
Water Temp. Sensor
Intake Air Temp.
Sensor

Correction

Turbo Pressure Sensor

Injection Timing

EDU

Injector
201EG45

EG-208

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

8. During Starting Control

Injection Volume Control
The starting injection volume is determined by adjusting the basic injection volume in accordance with the
starter on signals (on time) and coolant temperature sensor signals and engine speed signal. When the engine
is cold, the coolant temperature will be lower and the injection volume will be greater.
ECM
Basic Injection
Volume
+

Starter Signal

Correction

Water Temp.
Sensor
Crankshaft
Position Sensor
224EG50

Injection Timing Control

To determine the starting injection timing, the target injection timing is corrected in accordance with the
starter signals, water temperature, and engine speed.
When the water temperature is low, if the engine speed is high, the injection timing is advanced.
ECM
Starter Signal
Target Injection
Timing Correction

Water Temp.
Sensor
Crankshaft
Position Sensor
224EG51

EG-209

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

9. Idle Speed Control

ISC correction is controlled as shown below.
ECM

Accelerator
Pedal Position
Sensor
Water Temp.
Sensor
Vehicle Speed
Sensor

Target Speed
Calculation

Starter Signal
A/C Signal*
Idle-up Signal
Comparison

Injection Volume
Correction

Actual Engine Speed

Crankshaft
Position Sensor

233EG14

*: Models with air conditioning system

EG

EG-210

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

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 the
accelerator pedal position sensor and the crankshaft position sensor.
To control fuel pressure, signals sent to the SCV (Suction Control Valve) of the supply pump regulate
the suction volume, and signals sent to pressure discharge valve of the common-rail regulate the
discharge volume, so that the pressure detected by the fuel pressure sensor matches the target injection
pressure.

Crankshaft Position
Sensor

Accelerator Pedal
Position Sensor

ECM

Calculation of
Target Injection
Pressure

Fuel Pumping

Supply Pump
Feed Pump

Fuel Pressure
Sensor

SCV

Plunger

Common-rail

Pressure Discharge
Valve

Control
Suction
Volume

Fuel Injection

Fuel Tank

Injector

EDU

04ZEG025Y

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

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 pedal
position sensor and the crankshaft position sensor.
To control fuel pressure, signals sent to the SCV (Suction Control Valve) of the supply pump regulate
the suction volume, so that the pressure detected by the fuel pressure sensor matches the target injection
pressure.

Crankshaft Position
Sensor

Accelerator Pedal
Position Sensor

EG

ECM

Calculation of
Target Injection
Pressure

Fuel Pumping

Supply Pump
Feed Pump

Fuel Pressure
Sensor

SCV

Plunger

Common-rail Pressure Limiter

Controls
Suction
Volume

Fuel Injection

Fuel Tank

Injector

EDU

002CV36Y

*: Target injection pressure

1KD-FTV engine

32 160 MPa

2KD-FTV engine

30 160 MPa

EG-212

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

System Operation
1) General
The ECM controls the opening of the SCV in order to regulate the volume of fuel that is pumped by the
supply pump to the common-rail. Consequently, the fuel pressure in the common-rail is controlled to the
target injection pressure.
2) SCV Opening Small
(a) When the opening of the SCV is small, the fuel suction area is kept small, which decreases the
transferable fuel quantity.
(b) When the plunger strokes fully, however, the suction volume becomes small due to the small suction
area. Therefore, the difference of the volume between the geometry volume and the suction volume
is in vacuum condition.
(c) Pumping will start when the fuel pressure has become higher than the common-rail pressure.

Fuel Pumping Mass

Plunger TDC

Plunger BDC

Pumping
Starting Point

Cam
Stroke

SCV

Small Suction
Area
(a)

(b)

(c)

00MEG34Y

EG-213

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

3) SCV Opening Large

(a) When the opening of the SCV is large, the fuel suction area is kept large, which increases the
transferable 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-rail
pressure.
Fuel Pumping Mass
Pumping
Starting Point

EG

Cam
Stroke

SCV

Large Suction
Area
(a)

(b)

(c)

00MEG35Y

EG-214

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

11. Pilot Injection Control

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

State

Pilot Injection

Ordinary Injection

Pilot Injection Main Injection

Fuel Injection

Combustion
Pressure

168EG23

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

Accelerator Pedal
Position Sensor

Crankshaft
Position Sensor
Engine Speed

ECM
Basic Pilot Injection
(Volume, Timing, Interval)
Intake Air Temp.
Sensor
Correction

Water Temp. Sensor

Turbo Pressure Sensor

Pilot Injection
(Volume, Timing, Interval)

EDU

Injector
201EG45

EG-215

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

12. Intake Shutter Control

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

Intake Shutter
Valve Position
Sensor

Intake Shutter Valve

Control Motor
Engine Speed
Vehicle Speed
Intake Shutter
Valve

Water Temp.
ECM

Intake Air Temp.

Accelerator Pedal
Position

Intake Air Pressure

Ignition Switch
271EG140

EG

EG-216

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

13. Swirl Control

General
D On the models with 1KD-FTV engine and 2KD-FTV High Version engine compliant with EURO IV
emission 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 control
valve with 3-stage control is used.
Operation
1) General
The ECM determines the swirl control valve position based on the engine conditions (engine speed and
accelerator 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 smoke
emissions.
D In the low engine speed range, the ECM closes the swirl control valve to strengthen the swirl in the
combustion 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 swirl
control valve.

Intake Port

Vacuum
Pump

Swirl Control
Valve

Combustion Chamber

Accelerator Pedal Position

Engine Speed

Actuator

ECM
VSV

271EG90

EG-217

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

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 smoke
emissions.
D In the low engine speed range, the ECM closes the swirl control valve to strengthen the swirl in the
combustion 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.

Vacuum
Pump

EG

Intake
Port
Swirl
Control
Valve

Combustion Chamber

VSV
Accelerator
Pedal Position
Engine Speed

Actuator
ECM

VSV

041EG07

EG-218

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

14. Turbo Charger Control

General
D On the models with 1KD-FTV engine, a turbocharger control system is used.
D The ECM controls the nozzle vane position using the turbo motor driver, in order to obtain the calculated
target turbo pressure appropriate to the engine operating conditions.
D The ECM calculates the optimal nozzle vane position in accordance with the driving conditions (engine
speed, injection volume, atmospheric pressure, and water temperature etc), and sends a target nozzle
vane position signal to the turbo motor driver. The turbo motor driver controls the nozzle vane position
in accordance with this signal and the actual nozzle vane position signal provided by the nozzle vane
position sensor.

DC Motor

Turbo Pressure
Sensor

Nozzle Vane
Position
Sensor
Actual Nozzle
Vane Position

Atmospheric
Pressure
Sensor
Nozzle Vane
Position Control

ECM

Turbo Motor
Driver

Target Nozzle Vane Position Signal

Turbocharger Control Status

Crankshaft
Position
Sensor
Injector
Water Temp.
Sensor
Intake Air
Temp.
Sensor
271EG141

EG-219

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Construction
1) General

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

DC Motor

EG
Nozzle Vane
Position Sensor
Turbine
Wheel
Linkage

Nozzle Vane
Driven Arm

Drive Arm

Full-close Stopper
Unison Ring

271EG142

EG-220

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Service Tip
D To control the nozzle vane position, the turbo motor driver renders the contact position of the
linkage with the full-close stopper (thus fully closing the nozzle vane) as the zero point for the
nozzle vane position sensor.
D If the turbocharger has been reinstalled or replaced, turn the ignition switch from ON to OFF
once, 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 not
serviceable in the field. For this reason, if the linkage does not come in contact with the
full-close stopper during an inspection, the turbocharger assembly must be replaced.
Never attempt to loosen or tighten the locknut of the full-close stopper because it will adversely
affect the performance of the engine.
D For details, refer to the Hilux Repair Manual.
Linkage

Open

Full-close
Stopper

Close
Lock Nut

271EG143

EG-221

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

2) Nozzle Vane Position Sensor

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

Hall IC

EG
4.5
Magnetic Yoke
Full Closed

Sensor Vane

Output
Voltage
(V)
0.5

Full Open

Nozzle Vane Position

Full Closed

Full Open
271EG148

Sensor Vane
271EG147

"

System Diagram A
Nozzle Vane
Position Sensor
Magnetic Yoke

Nozzle Vane
Position Sensor
Magnetic Yoke

VNVC
VTA1

Hall
IC
Hall
IC

VNE2
VCS
VTA2

VCX1

Turbo
Motor
Driver

Hall
IC

VSX1
E2X1

Turbo
Motor
Driver

E2S

Sensor Vane
Models Compliant with EURO IV
Emission Regulations

Sensor Vane

00LEG79IT

Except Models Compliant with

EURO IV Emission Regulations

EG-222

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Operation
1) At Engine Low Speed Range
When the engine is running in a low speed range, the DC motor presses down the linkage by a signal from
the turbo motor driver. The tip of the linkage rotates the unison ring counterclockwise through a drive
arm.
The unison ring contains a driven arm, which is placed through the cutout portion of the unison ring. This
driven arm also moves in the direction of the rotation of the unison ring. The fulcrum of the driven arm
is an axis that is integrated with the nozzle vane behind the plate. When the driven arm moves
counterclockwise, the nozzle vane moves toward the closing direction. This results in increasing the
velocity of the exhaust gas flowing to the turbine, as well as the speed of the turbine. As a result, torque
is improved when the engine is running at low speeds.
DC Motor
Nozzle Vane
Linkage

Linkage

Gas Flow

Plate

Fulcrum

Unison Ring
Drive Arm

Driven Arm

Driven Arm

Cutout Portion
271EG144

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 a
signal from the turbo motor driver. With this, the driven arm moves clockwise and this opens the nozzle
vane and holds the specified supercharging pressure. Thus, lowering the back pressure and improving
the output and fuel consumption.

271EG145

EG-223

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

15. EGR Control

General
D On the models for G.C.C. Countries and models compliant with EURO I, EURO III, EURO IV and Tier
1 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 peak
temperature in the engine combustion chamber, which is accomplished by introducing a small amount
of inert gas into intake manifold.
D The table below lists the differences between the EGR system on the 1KD-FTV and 2KD-FTV engines.

Engine

1KD-FTV
1KD
FTV

2KD-FTV
2KD
FTV

EGR Valve
VSV
Position Sensor (for EGR Valve Close)

EGR Cooler Bypass

Switching Valve and VSV
(for EGR Cooler
Bypass Switching Valve)

Compliant
with EURO IV

Others

Compliant
with EURO IV

Others

Operation
D By sensing the engine driving conditions and actual amount of EGR valve opening*1, the ECM
electrically operates the E-VRV (for EGR valve control) and VSV (for EGR valve close)*2, which
controls 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 recirculating
exhaust 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 the
EGR control is stopped, in order to introduce the atmospheric pressure to the EGR valve diaphragm and
improve EGR valve closure response to maintain driveability.
D On the models compliant with EURO IV emission regulations, the ECM switches the bypass passage
of the EGR cooler via the VSV (for EGR cooler bypass switching valve) in order to optimize the
temperature of the EGR gas and clean exhaust gases.
*1: Models with EGR valve position sensor
*2: Models with VSV (for EGR valve close)

EG

EG-224

Intake
Shutter
Valve
Position
Sensor

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

Intake
Shutter
Valve

Intake Shutter Valve Control Motor

EGR Valve Position Sensor*1
Vacuum
Damper

Vacuum
Pump

Crankshaft
Position Sensor
Accelerator Pedal
Position Sensor
Water Temp.
Sensor
Turbo Pressure
Sensor
Intake Air
Temp. Sensor
Air Flow
Meter*3

ECM
Intake
Manifold

EGR
Valve
E-VRV
(for EGR Valve Control)

Engine

VSV*2
(for EGR Valve Close)

Atmospheric
Pressure
Sensor

041EG09

Exhaust Manifold
Except Models Compliant with EURO IV Emission Regulations

Intake
Shutter
Valve
Position
Sensor

Intake
Shutter
Valve

Intake
EGR Valve Position Sensor
Shutter
Valve
Control
Vacuum
Pump
Motor
Vacuum
Damper

VSV (for EGR

Valve Close)

ECM
Atmospheric
Pressure
Sensor

EGR
Valve

Intake
Manifold

EGR Cooler
Bypass
Switching
Valve

EGR Cooler

Engine
Exhaust Manifold

Turbo Pressure Sensor

Intake Air Temperature
Sensor
Air Flow Meter

E-VRV
(for EGR
Valve Control)

VSV (for EGR Cooler Bypass

Switching Valve)
Bypass Passage

Models Compliant with EURO IV Emission Regulations

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

Crankshaft Position Sensor

Accelerator Pedal Position
Sensor
Water Temperature Sensor

03XEG18Y

EG-225

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

16. Oil Maintenance Management System

General
D On the models for Europe, an oil maintenance management system is used. This system determines the
deterioration conditions of the engine oil and illuminates an engine oil change reminder light to inform
the driver when the engine oil and the oil filter must be changed. Accordingly, the maintenance intervals
(30000 km maximum) that correspond to the actual deterioration conditions of the engine oil have been
realized.
D This system indirectly determines the deterioration of the engine oil based on the information provided
by the ECM.

EG

System Diagram
Combination Meter
Engine Oil
Change Reminder
Light

ECM
D Engine Speed
D Injection Volume
D Injection Timing
D Intake Air Mass

Soot
Volume

Meter
ECU

ODO/TRIP
Switch
Vehicle
Speed Sensor
291EG34

Layout of Components
Combination Meter
D Engine Oil Change Reminder Light
D ODO/TRIP Switch

ECM

291EG18

EG-226

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

System Operation
D This system determines the deterioration of the engine oil in accordance with the soot volume in the
engine 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 pulse
signals and transmits the signals to the meter ECU. The meter ECU counts the pulse signals as the soot
volume, and blinks an engine oil change reminder light when the cumulative value gets closer to a
predetermined value, and illuminates the reminder light when the cumulative value reaches the
predetermined value. Thus, this system informs the driver that the engine oil and the oil filter must be
changed.
"

Soot Generation Conditions A

Large

Large
Soot
Contamination
Volume

Soot
Contamination
Volume

Small

Small
Large z Air-fuel Ratio ! Small

Early z Injection Ending Timing ! Late

Relationship to Air-fuel Ratio

Relationship to Injection Ending Timing

224EG35

"

224EG36

Soot Pulse Signal A

224EG37

Normal

Soot Pulse Signal

(1 Count)

291EG26

During Soot pulse transmission

D In addition to controlling the illumination of the engine oil change reminder light by calculating the soot
volume, the ECM blinks the reminder light when the vehicle travel distance reaches 25000 km, and
illuminates it when the travel distance reaches 30000 km. Thus, this function enhances the reliability of
the system.
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 should
be changed at 2-year intervals at the maximum.

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

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

EG-227

17. Diagnosis
D The diagnosis system of the 1KD-FTV and 2KD-FTV engine uses the EURO-OBD (Europe On-Board
Diagnosis) that complies with European regulations.
D When the ECM detects a malfunction, it makes a diagnosis and memorizes 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) to
the 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 ECM data can be read out. Moreover, the ACTIVE
TEST 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.
Service Tip
To clear the DTC that is stored in the ECM, use an intelligent tester II or disconnect the battery
terminal or remove the EFI fuse for 1 minute or longer.

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

EG