Model Outline KD Series Engine Chassis Body Body Electrical

Contents
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Model KD Series Engine Chassis Body Body Electrical
Outline 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 KD Series Engine Chassis Body Body Electrical
Outline
Engine Overall
1KD-FTV / 2KD-FTV
– TOYOTA D-4D, 3.0 / 2.5 liter, in-line 4-cylinder,
16 valve DOHC with turbocharged diesel
engine

1KD-FTV 2KD-FTV
Model Outline KD Series Engine Body Body Electrical
Chassis
Engine Overall
1KD-FTV / 2KD-FTV Specifications
1KD-FTV 2KD-FTV
Item (HILUX, (HILUX, FORTUNER,
FORTUNER) INNOVA)
No. of Cylinders & Arrangement 4-Cylinder, In- 
line
Valve Mechanism 
16-Valve DOHC,
Fuel System Belt & Gear Drive

Intercooler Common-Rail Type Without / With *2
Displacement cm3 (cu. in.) With 2,492 (152.2)
Bore x 2,982 (182.0)
92.0 x 93.8
Stroke mm (in.) 96.0 x 103.0 (3.62 x 3.69)
Compression Ratio (3.78 x 4.06) 18.5
Max. Output 18.4 75 @ 3,600
120 @ 3,400
kW @ rpm 88 @ 3,600 *2
200 @ 1,400 ~ 3,200
Max. Torque 343 @1,400 ~
260 @ 1,600 ~ 2,400 *1
N·m @ rpm 3,200
320 @ 2,000 *2
*1: 2KD-FTV High Version
*2: 2KD-FTV High Version (HILUX for Thai only)
Model KD Series Engine Chassis Body Body Electrical
Outline
Engine Overall
Features
– Engine compartment
Rotary Solenoid Type
VN Type Turbocharger
Diesel Throttle
(1KD only)

Photo: 1KD-FTV

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

Front
Model KD Series Engine Chassis Body Body Electrical
Outline
Valve Mechanism
Timing Belt
– Maintenance interval: replace at every 150,000 km
Oil Pump Drive Gear
Camshaft
Timing Crankshaft Timing Gear
Pulley No. 2
Supply Pump Drive Gear
Timing
Belt

Automatic
Belt
Tensioner

Camshaft
Timing
Pulley No. 1 Vacuum Pump Drive Gear

Idle Gear
Model KD Series Engine Chassis Body Body Electrical
Outline
Lubrication System
Lubrication System
– Overall
• Lubrication is fully pressurized and all oil passes
through an oil cooler and oil filter

Oil Filter

Oil Cooler
Model Outline KD Series Engine Body Body Electrical
Chassis
Intake and Exhaust System
Intake Shutter Valve
– Rotary solenoid type intake shutter valve is used to
improve EGR performance
Engine Valve
Purpose
Condition Position
Full Reduced Diesel Intake Shutter Valve
Starting
Open Smoke Position Sensor
Small -
Controls EGR
Running Full
amount
Open
Full Reduced noise
Stop
Close and vibration
Air flow

Intake Shutter Valve

Rotary Solenoid type Motor

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

Rotary Solenoid
Intake Shutter Valve Type Motor
Position Sensor

Steel Layer
Magnet
Hall IC

Magnet
Magnet
Model Outline KD Series Engine Body Body Electrical
Chassis
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 Body Body Electrical
Chassis
Intake and Exhaust System
Swirl Control Valve (1KD only)
– Swirl control valve is provided to realize clean
emission
Intake Manifold

Actuator

Swirl Control Valve

VSV for SCV

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

Intake
Air

At low engine speed,

SCV is closed to
strengthen the swirl

Actuator Vacuum
Pump
Engine Speed

Engine
VSV ECU
ON / OFF

Accelerator
Pedal Opening
Model Outline KD Series Engine Body Body Electrical
Chassis
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
– Nozzle Vane is driven by DC motor

DC Motor

Nozzle Vane
Position Sensor
Turbine
Wheel
Motor Rod

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

DC Motor

Intake Air

Nozzle Vane
Position Sensor
Turbine Reduction
Wheel Gears
Motor
Rod

Link
Full-
Nozzle Vane
Close
Stopper
Model Outline KD Series Engine Body Body Electrical
Chassis
Intake and Exhaust System
Variable Nozzle Vane Type Turbocharger (1KD only)
– Construction
Motor Rod
Gas Flow
Drive Arm

Turbine
Wheel

Link
Unison Ring
Nozzle
Vane
Driven Arm

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

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

Link is bumped
IG to full-close
ON  stopper
OFF

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

Click!

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

Waste Gate Actuator

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

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

Signals Pressure
Fuel Pressure Limiter
Sensor Common-rail

Injector

Pressure
Switch

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

Injector

Pressure
Switch

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

Signals Pressure
Fuel Pressure Limiter
Common-rail
Sensor
(Stores high-pressure fuel)

Injector
(Injects high-pressure fuel)

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

: High-pressure (Max. 160 MPa)

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

System
SCV Governor
Timer
ECU

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

Injection Pipe Injector

Fuel Inlet Pipe

Common-rail
• Fuel Pressure Sensor
Supply Pump • Pressure Limiter
• SCV (Suction Control Valve)
• Fuel Temp. Sensor
Model KD Series Engine Chassis Body Body Electrical
Outline
Common-rail System
Supply Pump
– Supplies the high pressure fuel to the common-rail
– Driven by crankshaft

To Common-rail
(Outlet)
From Fuel Filter
(Inlet)

To Fuel Tank
(Return)

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

Check Eccentric and Delivery

Ring Cam Valve
Valve

Plunger
Feed

Pump

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

Ring Cam

Plunger

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

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

Click!

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

Plunger A: Suction Plunger A: Pumping

Plunger B: Pumping Plunger B: Suction
Check

Valve
Plunger
A

SC
V

Plunger B

: From Feed Pump : To Common-rail

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

Click!

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

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

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

Click!

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

Click!

Movie
Model KD Series Engine Chassis Body Body Electrical
Outline
Common-rail System
Supply Pump
– The SCV opening regulates the pumping volume to
control fuel pressure
[Fuel Pressure Control]
Fuel Pressure
Sensor

Common-rail
pressure
SCV (Feedback)

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

Fuel
Pressure
Sensor

Common-rail

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

Output characteristic
Sensor Tip

Output Voltage (V)

4.04

2.44

1.0

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

Injector
Compensation
Code
Return to From
Fuel Common-rail
Tank

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

Return to From
Fuel Common-rail
Tank

Piston

Nozzle

Spring

Nozzle

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

Solenoid
Solenoid

TWV
Small
Return
Orifice
From Large
Common-rail
Orifice

Click!

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

Main
Injection Pilot
Volume

NOx and
engine noise

Heat
Release
Value

TDC TDC

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

EDU
Battery High
DC / DC Voltage
Converter

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

DTC No. Detection Item Trouble Area

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

DTC No. Detection Item Detection Condition

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

Difference of common-rail pressure before

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

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

DTC No. Detection Item Fail-safe

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

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

P0190 Fuel Rail Pressure Sensor

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

DTC No. Detection Item Trouble Area

• Open or short in EDU circuit

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

• Open or short in (SCV) circuit

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

• Short in supply pump (SCV) circuit

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

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

DTC No. Detection Item Detection Condition

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

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

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

DTC No. Detection Item Fail-safe

P0200
Injector Circuit / Open
(97)

P0627 Fuel Pump Control Circuit Limits engine power

(78) / Open

P1229
Fuel Pump System
(78)

Injector Correction
P1601
Circuit -
(89)
Malfunction
(EEPROM)
Model KD Series Engine Chassis Body Body Electrical
Outline
Common-rail System
Service Point for Common-rail System
– Supply pump initialization and calibration
– Common-rail replacement
– Reprogramming of injector compensation code
– Replace a new parts
– Replace a new pipe
– Check fuel leak (Leakage Pipe No.1 / Fuel System)
– Power Balance Check
Model KD Series Engine Chassis Body Body Electrical
Outline
Fuel System
Fuel Filter
– Replace fuel filter element only
Priming Fuel Filter
Pump Warning Switch

To Supply Pump
From Fuel Tank

Fastener Nut

Filter Housing
(Plastic)

Filter Element

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

From Fuel Tank To Supply Pump

Fastener Nut

Filter Element Filter Housing

(Plastic)

Fuel Sedimenter Level

Warning Switch
Model KD Series Engine Chassis Body Body Electrical
Outline
Fuel System
Fuel Warning System
– Fuel filter clogging is detected by fuel filter warning
switch
Fuel Filter
Warning Switch Fuel System
Warning
Light

Cloggin
g
Combination Meter

Fuel Filter

- Fuel Filter Maintenance Interval -

Fuel system warning light has been illuminated
Model KD Series Engine Chassis Body Body Electrical
Outline
Fuel System
Fuel Warning System
– System Diagram
Combination Meter

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

To Supply Pump

Filter Element

Fuel Filter Fuel Sedimenter Level Warning Switch

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

Diaphragm

To Supply Pump To Supply Pump

Filter Element Negative

Pressure

Normal Fuel Filter Fuel Filter Clogged Up

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

Warning
Warning Priority
Method

Sedimenter
Warning 1
Blink

Fuel Filter
Warning 2
ON
Model KD Series Engine Chassis Body Body Electrical
Outline
Fuel System
Fuel Warning System
– Detection conditions
After the driving for 30 min. or more

Fuel Filter Warning Switch Condition

OFF for 10 min. OFF is detected for 2

or more or times during 1 trip

The warning light keeps ON until the reset operation is done

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

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

One-way Crankshaft Pulley

Clutch Speed
Locked

One-way
Clutch
Free

Alternator
Pulley Speed

Engine
Pulley Speed

Fluctuation
(rpm)

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

Idler Pulley
Air Conditioner
Compressor Pulley

Water Pump
Idler Pulley Pulley

Alternator Pulley
with Shock
Absorbing Function

Idler Pulley for

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

Engine Oil Change

Engine ECU Reminder Light

• Engine Speed Blink or ON

• Injection Volume
• Injection Timing Meter ECU
• A/F Ratio

Soot
Volume ODO / TRIP
Switch
Soot Volume
Calculation

Vehicle

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

Soot
Volume

Retard

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

Engine Oil Change

Condition
Reminder Light

Mileage = 35,000 km ~ 40,000 km

or
Specified Soot Volume A

Mileage = 40,000 km or more

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

Magnet
Hall IC 5

Output Voltage (V)

VC 3.51

VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full
Intake Shutter Open)
Intake Shutter Valve
Valve Position Opening Angle (°)
Sensor
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Variable Nozzle Vane Type Turbocharger (1KD only)
– Nozzle Vane Position Sensor
• Non-contact type position sensor

Hall ICs
Output characteristic of
main, sub sensor

Output Voltage (V)

4.5

e n
Magnets Op
Cross-section 2.5 VN
e
C los
0 VN
0.5

-55  55  -55 0

55
Sensor shaft rotation angle ()
Model Outline KD Series Engine Chassis Body Body Electrical
Reference
Fuel Cooler
– A fuel cooler cools the return fuel
– It is used on the model equipped with an intercooler

Front

Fuel Cooler

(Aluminum)

From Supply
Pump / Injector

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

Fin

Cross
Section

To Fuel Tank From

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

VCP1
Magnets
VPA1

Output Voltage (V)

EP1 5

VPA2
VCP2

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