ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-147

JENGINE CONTROL SYSTEM

1. General
The engine control system of the 1KD-FTV and 2KD-FTV engines has the following system.
D 2KD-FTV
System Outline 1KD-FTV D 2KD-FTV
High Version
Fuel Injection Based on the signals received from the sensors, the engine ECU
Volume Control determines the fuel injection volume in accordance with the engine f f
(See page EG-156) condition.
Fuel Injection Based on the signals received from the sensors, the engine ECU
Timing Control determines the fuel injection timing in accordance with the engine f f
(See page EG-157) condition. EG
During Starting
To facilitate startability, the engine ECU optimally controls the
Control f f
injection volume and injection timing during starting.
(See page EG-158)
The engine ECU determines the idle speed in accordance with the
Idle Speed Control
engine condition, and controls the fuel injection volume in order to f f
(See page EG-159)
maintain the target idle speed.
Fuel Pressure Based on the signals received from the sensors, the engine ECU
Control determines the fuel pressure via SCV (Suction Control Valve) in f f
(See page EG-160) accordance with the engine condition.
Based on the signals received from the sensors, the engine ECU
Pilot Injection
determines pilot injection volume/timing, and interval (between
Control f f
pilot injection and main injection) in accordance with the engine
(See page EG-163)
condition.
Controls the length of time when the current is applied to the glow
Glow Plug Control f f
plugs, in accordance with the coolant temperature.
D Controls the intake shutter valve (throttle valve) opening angle
Intake Shutter
in accordance with the engine condition.
Control f f
D Fully close the intake shutter valve (throttle valve) in order to
(See page EG-164)
reduce the vibration when the engine is stopped.
Based on the signals received from the sensors, the engine ECU
Swirl Control
controls the vacuum that is directed to the actuator via the VSV, in f —
(See page EG-164)
order to open and close the valve.
Turbocharger
Based on the signals received from the sensors, the engine ECU
Control f —
controls the actuator in accordance with the engine condition.
(See page EG-165)
EGR Control Controls the EGR volume via EGR valve in accordance with the
f f
(See page EG-169) engine condition.
Air Conditioner By controlling the air conditioner compressor ON or OFF in
f f
Cut-Off Control*1 accordance with the engine condition, drivability is maintained.
Engine Prohibits fuel injection if an attempt is made to start the engine with
f f
Immobilizer*2 an invalid ignition key.
Diagnosis When the engine ECU detects a malfunction, the engine ECU
f f
(See page EG-171) diagnoses and memorizes the failed section.
When the engine ECU detects a malfunction, the engine ECU stops
Fail-Safe
or controls the engine according to the data already stored in the f f
(See page EG-171)
memory.
*1:Models with Air Conditioner
*2:Models with Engine Immobilizer System
EG-148 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.

VLU #1
INTAKE SHUTTER VALVE No. 1 INJECTOR
POSITION SENSOR #2
No. 2 INJECTOR
#3 EDU
No. 3 INJECTOR
G #4
CAMSHAFT POSITION SENSOR No. 4 INJECTOR
INJF

NE
CRANKSHAFT POSITION SENSOR
PCV
SUCTION CONTROL VALVE

PCR1
FUEL PRESSURE SENSOR
INTAKE SHUTTER CONTROL
LUSL
PIM Torque Motor (Rotary Solenoid type)
TURBO PRESSURE SENSOR

EGR CONTROL
THA
INTAKE AIR TEMP. SENSOR
EGR Vacuum Regulating Valve
(for EGR Valve Control)
THW Engine EGRC
WATER TEMP. SENSOR
ECU VSV (for EGR Valve Close)*1

ACCELERATOR PEDAL VPA

POSITION SENSOR VPA2 GLOW PLUG CONTROL
GREL
Glow Plug Relay
VG
AIR FLOW METER*1
IREL EDU RELAY
THF
FUEL TEMP. SENSOR
SCV
VSV (for Swirl Control Valve)*1
THIA
INTAKE AIR TEMP. SENSOR*2
TURBOCHARGER CONTROL*1

EGR VALVE EGLS VNTO

POSITION SENSOR*3 Turbo Motor Driver
VNTI
STP Nozzle Vane
STOP LIGHT SWITCH Position Sensor
ST1–

ALT DC Motor
ALTERNATOR

271EG132

(Continued)
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-149

IGNITION SWITCH A/ C AMPLIFIER*7

STA
D Starting Signal (ST Terminal) ACT
IGSW Magnetic Clutch Actuation Signal
D Ignition Signal (IG Terminal)
AC1
Engine Idle-Up Signal

CCS
CRUISE CONTROL MAIN SWITCH*4

BATT
BATTERY COMBINATION METER
EG
W Check Engine
MREL Engine ECU Warning Light
MAIN RELAY
+B GIND
Glow Indicator Light
IMO
TRANSPONDER KEY ECU*5 IMI PI Cruise MAIN
Indicator Light*4
SPD
TC Vehicle Speed Signal
SIL
DLC3 DM
WFSE Injection Volume Signal*8

TACH
Tachometer
TRANSMISSION CONTROL ECU*6 CAN+
THWO
Water Temp. Signal
ECT CONTROL CAN–

271EG133

*1: Only for 1KD-FTV Engine

*2: Only for Models with Intercooler
*3: Only for 2KD-FTV Engine
*4: Only for Models with Cruise Control System
*5: Only for Models with Engine Immobilizer System
*6: Only for Models with Automatic Transmission
*7: Only for Models with Air Conditioner System
*8: Only for Models with Multi Information Display
EG-150 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

3. Engine Control System Diagram

Accelerator Pedal
Position Sensor

Ignition Switch Signal

Stop Light Switch Signal Glow Relay
Air conditioner Signal*1
Vehicle Speed Signal
Suction Control
Valve Fuel Temp.
Engine Sensor
ECU

Supply Pump

Atmospheric
Pressure Sensor

VSV*2

Common-Rail
(EGR Valve Close) EDU
Intake Air Relay
Fuel Pressure Intake Air Temp.
Sensor Temp. Sensor*2 Sensor*3
EDU
Intake
E-VRV
Shutter
EGR Valve
Assy. Position Sensor*4
Turbo Pressure
Air Flow Meter*2 Sensor

Intake Air
Temp. Sensor*4
D DC Motor*2
D Nozzle Vane
Glow Plug
Position Sensor*2
VSV*2
(Swirl
Injector
Turbo Motor Control
Valve)
Driver*2
Water
Temp.
Sensor
Camshaft
Position Sensor
Crankshaft
Position Sensor

271EG134

*1: Only for Models with Air Conditioner *3: Only for Models with Intercooler
*2: Only for 1KD-FTV Engine *4: Only for 2KD-FTV Engine
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-151

4. Layout of Main Components

E-VRV EDU
Turbo Pressure Sensor

Air Flow Meter*1

Intake Air
Temp. Sensor*2
EG
Glow Plug
Intake Air
Temp. Sensor*3
Injector
Intake Shutter Valve
Fuel Position Sensor
Pressure Torque Motor
Sensor (Rotary Solenoid type) VSV*1
(EGR Valve Close)
Water EGR Valve
Temp. Position Sensor*2 Check Engine
Sensor Warning Light

Glow
VSV*1 Indicator Light
(Swirl Control
Valve) Transmission
Engine ECU
Control ECU*4

Common-Rail

Crankshaft
Position Sensor
Fuel Temp.
Camshaft Position Sensor
Sensor

Stop Light
SCV Switch

Supply Pump DLC3 Accelerator Pedal

Position Sensor
Turbo Motor
Driver*1
LHD Model 271EG135

*1: Only for 1KD-FTV Engine

*2: Only for 2KD-FTV Engine
*3: Only for Models with Intercooler
*4: Only for Models with Automatic Transmission
EG-152 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

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
The engine ECU effects overall control of the engine
control system to suit the operating conditions of the
Engine ECU 32-bit CPU 1
engine in accordance with the signals provided by the
sensors.
The EDU is used to drive the injector at high speeds. The
EDU has realized high-speed driving under high fuel
EDU DC/ DC Converter 1 pressure conditions through the use of a DC / DC
converter that provides a high voltage, quick-charging
system.
Turbo Pressure Semiconductor This sensor uses built-in semiconductors to detect the
1
Sensor Silicon Chip Type intake manifold pressure.
Atmospheric Semiconductor This sensor, which is built into the engine ECU, uses
1
Pressure Sensor Silicon Chip Type semiconductors to detect the atmospheric pressure.
Fuel Pressure Semiconductor This sensor uses built-in semiconductors to detect the
1
Sensor Strain Gauge Type internal pressure of the common-rail.
Crankshaft Position Pick-up Coil Type This sensor detects the engine speed and performs the
1
Sensor (Rotor Teeth / 36-2) cylinder identification.
Camshaft Position Pick-up Coil Type
1 This sensor performs the cylinder identification.
Sensor (Rotor Teeth / 5)
Air Flow Meter This sensor uses a built-in hot-wire to directly detect the
Hot-wire Type 1
(1KD-FTV Engine) intake air volume.
Water Temperature This sensor detects the engine coolant temperature by
Thermistor Type 1
Sensor means of an internal thermistor.
D This sensor, which is provided at the air cleaner outlet,
detects the intake air temperature by means of an
Intake Air
Thermistor Type 1 internal thermistor.
Temperature Sensor
D On the 1KD-FTV engine, this sensor is built into the
airflow meter.
Intake Air This sensor, which is provided only on the models with
Temperature Sensor Thermistor Type 1 an intercooler, detects the intake air temperature past the
(for Intercooler) intercooler.
Fuel Temperature This sensor detects the fuel temperature in the supply
Thermistor Type 1
Sensor pump by means of an internal thermistor.
Intake Shutter Valve This sensor detects the intake shutter valve (throttle
No-contact Type 1
Position Sensor valve) opening angle.
D This sensor detects the amount of pedal effort applied
to the accelerator pedal.
Accelerator Pedal
No-contact Type 1 D The basic construction and operation of this sensor
Position Sensor
are the same as in the 1TR-FE and 2TR-FE engines.
For details, see page EG-46.
EGR Valve Position
This sensor detects the actual amount of the EGR valve
Sensor Contact Type 1
opening.
(2KD-FTV Engine)
SCV The SCV position is controlled by the signals from the
Linear Solenoid
Suction Control 1 ECU, and a fuel volume that suits the SCV position is
Valve
Valve drawn into the pumping portion (plunger portion).
8-hole Type The injector contains a solenoid valve that opens and
(1KD-FTV Engine) closes to increase or decrease the pressure in the control
Injector 4
6-hole Type chamber. This causes the nozzle needle to open and close
(2KD-FTV Engine) the valve, which results in fuel injection.
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-153

Engine ECU
D The 32-bit CPU of the engine ECU is used to increase the speed for processing the signals.
D Each of the 2KD-FTV engine and the 2KD-FTV High Version engine is equipped with an engine ECU
that contains an engine control program that differs from each other. However, both engine models share
the same mechanical components.
D On the models equipped with the A340E and A340F automatic transmissions, the engine ECU maintains
communication with a separate, independent ECT ECU through CAN (Controller Area Network). Thus,
engine control is effected in coordination with ECT control.

Turbo Pressure Sensor

The turbo pressure sensor consists of a semiconductor which utilizes the characteristic of a silicon chip that
EG
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 engine ECU in an amplified form.

Sensor Unit
(V)
5

Output
Voltage

0 (kPa)
100 250
Intake Manifold Pressure
271EG136

Fuel Pressure Sensor

The fuel pressure sensor consists of a semiconductor which utilizes the characteristic 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 engine ECU, in order to
constantly regulate the fuel at an optimal pressure.

Detection Portion
(V)

Output
Voltage

(MPa)
Fuel Pressure
271EG137
EG-154 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

Crankshaft Position Sensor and Camshaft Position Sensor

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
pulse for every 2 revolution of the crankshaft.

Camshaft Position Sensor

Camshaft
Position Sensor

34 Pulse/360_ CA 5 Pulse/720_ CA

224EG41

" Sensor Output Waveforms A

5 Pulse/720_ CA

180_ CA 180_ CA 180_ CA

34 Pulse/360_ CA 34 Pulse/360_ CA

271EG138
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-155

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 5

Output EG
Magnet Voltage
(V)

Intake Shutter Valve 0 100

(Throttle Valve) Intake Shutter Valve Position Ratio (%)

271EG82 271EG83
EG-156 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

6. Fuel Injection Volume Control

The engine ECU calculates two types of values: the basic injection volume and the maximum injection
volume. Then, the engine ECU compares the basic and maximum injection volumes, and determines the
smaller calculated value to be the final injection volume.

" Basic Injection Volume A

Accelerator Crankshaft
Pedal Position Position Sensor
Sensor Engine Speed

Engine ECU

Calculation of ISC* Correction

Basic Injection
Volume Water Temp. Sensor

224EG44

*: Idle Speed Control

" Maximum Injection Volume A

Engine ECU

Basic / Maximum
Injection Volume
(Map data inside of ECU)
Crankshaft
Position Sensor
Engine Speed

Water Temp. Sensor

Maximum Injection
Fuel Temp. Sensor
Volume Correction

D Intake Air
Temp Sensor
D Turbo Pressure
Sensor
D Air Flow Meter*
Intake Air Volume*

224EG46

*: Only for 1KD-FTV Engine

 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-157

" Final Injection Volume Decision A

Engine ECU

Basic Injection Fuel

Volume Pressure

Comparison Final EDU

Maximum Injection EG
Volume
Injector

224EG48

7. Fuel Injection Timing Control

Fuel injection timing is controlled as shown below.

Crankshaft
Accelerator Pedal Position Sensor
Position Sensor Engine Speed

Engine ECU

Basic Injection Timing

Water Temp. Sensor

Intake Air Temp.

Correction
Sensor

Turbo Pressure Sensor

Injection Timing EDU Injection

201EG45
EG-158 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.

Engine ECU

Basic Injection
Volume

+ Starter Signal

Water Temp.
Correction
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.

Engine ECU

Starter Signal

Target Injection Water Temp.

Timing Correction Sensor

Crankshaft
Position Sensor

224EG51
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-159

9. Idle Speed Control

Fuel injection timing is controlled as shown below.

Engine ECU Accelerator

Pedal Position
Sensor

Water Temp. Sensor

Target Speed Vehicle Speed Sensor

Calculation EG
Starter Signal

A/ C Signal*

Idle-up Signal
Injection Volume
Comparison
Correction

Crankshaft
Actual Engine Speed
Position Sensor

*: with Air Conditioner

233EG14
EG-160 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

10. Fuel Pressure Control

General
Engine ECU calculates the target injection pressure (32 X 160 MPa/1KD-FTV, 30 X 160 MPa/2KD-FTV)
base on the engine conditions, that are the signals from the acceleration pedal position sensor and the
crankshaft position sensor.
To control fuel pressure, signals sent to SCV (Suction Control valve) of the supply pump regulate the
pumping volume, so that the pressure detected by the pressure sensor matches the target injection pressure.

Fuel Pressure Sensor Pressure Limiter

Common-rail

Injector
Supply Pump
D SCV
D Fuel Temp. Sensor
Crankshaft
EDU Position
Calculation of Sensor
target injection
pressure

Engine ECU Accelerator Pedal

Position Sensor

271EG139
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-161

System Operation

1) General
The engine ECU 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 decrease the
transferable fuel quantity.
(b) The plunger strokes fully, however, the suction volume becomes small due to the small suction area. EG
Therefore, the difference of the volume between the geometry volume and the suction volume is in
vacuum condition.
(c) Pumping will start at the time when the fuel pressure has become higher than the common-rail
pressure.

Fuel Pumping Mass Pumping

Plunger TDC Plunger BDC Starting Point

Cam
Stroke

SCV

Small Suction
Area

(a) (b) (c)

245EG13
EG-162 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 increase 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

Cam
Stroke

Large Suction
Area

(a) (b) (c)

245EG14
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-163

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 Ordinarily Injection

Pilot Injection
Main Injection
Fuel Injection

EG
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.

Crankshaft
Accelerator Pedal
Position Sensor
Position Sensor Engine Speed

Engine ECU

Basic Pilot Injection

(Volume, Timing, Interval)

Intake Air Temp. Sensor

Correction Water Temp. Sensor

Turbo Pressure Sensor

Pilot Injection
EDU Injection
(Volume, Timing, Interval)

201EG45
EG-164 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

12. Intake Shutter Control

The opening of the intake shutter valve (throttle valve) that is installed on the intake manifold is controlled
by the engine ECU in accordance with engine condition.
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 re-circulate
the exhaust gas in accordance with the driving condition.

Intake Shutter
Intake Shutter Valve
Valve Position
Control Motor
Sensor
Engine Speed
Vehicle Speed

Intake Shutter Water Temp.

Valve Engine
Intake Air Temp.
ECU
Accelerator Pedal Position
Intake Air Pressure
Ignition Switch

271EG140

13. Swirl Control (Only for 1KD-FTV Engine)

The engine ECU determines the swirl control valve position (open or closed) based on the engine conditions
(engine speed and accelerator pedal effort). Then, it switches the vacuum that is applied to the actuator
diaphragm via the VSV, in order to open and close the swirl control valve.
In the low engine speed range, the engine ECU closes the swirl control valve to strengthen the swirl in the
combustion chamber, thus promoting the mixture of fuel and air and stabilizing combustion. When the engine
speed increases to the medium or high-speed range, the engine ECU fully opens the swirl control valve. On
a cold engine, the engine ECU fully closes the swirl control valve to reduce the amount of white smoke
emissions.

Intake Port
Vacuum
Pump
Swirl Control
Valve
Accelerator Pedal Position
Combustion Chamber
Engine Speed

Actuator
Engine ECU

VSV 271EG90
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-165

14. Turbo Charger Control (Only for 1KD-FTV Engine)

General
D The engine ECU controls the nozzle vane position using the turbo motor driver, in order to obtain the
calculated target turbo pressure appropriate to the engine operating condition.
D The engine ECU 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.

EG

DC Motor Turbo Pressure

Sensor

Nozzle Vane
Position
Sensor Crankshaft
Atmospheric
Position Sensor
Pressure
Sensor
Nozzle Vane Injector
Actual Nozzle Position Control
Vane Position Engine ECU
Water Temp.
Sensor
Target Nozzle Vane Position Signal
Turbo Motor Intake Air
Driver Turbocharger Control Status Temp. Sensor

271EG141
EG-166 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

Construction
1) General
Variable nozzle vane device is established on the turbine (exhaust) side, and consisted of a DC motor,
nozzle vane position sensor, linkage, drive arm, unison ring, driven arms and nozzle vanes.

DC Motor

Nozzle Vane
Position Sensor
Turbine
Wheel

Linkage

Full-Close Stopper
Nozzle Vane

Driven Arm Unison Ring

Drive Arm

271EG142

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, see the Hilux Repair Manual.
Linkage

Full-Close
Open Stopper

Close

Lock Nut
271EG143
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-167

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

Sensor Vane Output

Magnetic Yoke
Voltage
(V)

Full Close Full Open 0.5

Nozzle Vane Position

Full Close Full Open

Sensor Vane
271EG147 271EG148

" System Diagram A

Nozzle Vane Position Sensor

Magnetic Magnet
Yoke

VCX1
VSX1 Turbo Motor
Hall IC
E2X1 Driver

Sensor Vane
Magnet

271EG149
EG-168 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

Fulcrum
Plate Unison Ring
Cutout Portion
Driven Arm
Drive Arm Driven Arm
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
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-169

15. EGR Control System

General
The table below lists the differences between the EGR system on the 1KD-FTV and 2KD-FTV engines,
as well as the differences in their control contents.

Engine Differences
A VSV (Vacuum Switching Valve) is provided for EGR valve close
1KD-FTV
control.
2KD-FTV An EGR valve pposition sensor is pprovided for detecting
g the EGR valve
2KD-FTV High Version position.
EG
EGR Control for 1KD-FTV Engine
D By sensing the engine driving conditions, the engine ECU electrically operates both the E-VRV (for EGR
valve control) and VSV (for EGR valve close), 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 1KD-FTV engine, 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.

Intake Shutter
Intake Valve Control Motor
Intake Shutter Shutter Vacuum
Valve Position Pump
Sensor
Valve Crankshaft Position
Sensor
EGR Vacuum Accelerator Pedal
Valve Damper Position Sensor
Engine
ECU Water Temp. Sensor
Turbo Pressure
Sensor
Atmospheric Intake Air Temp
Pressure Sensor
Sensor Air Flow Meter
Intake
Manifold
E-VRV
(for EGR Valve Control)

Engine VSV
(for EGR Valve Close)
Exhaust Manifold 271EG150
EG-170 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

EGR Control for 2KD-FTV Engine

By sensing the engine driving conditions and actual amount of EGR valve opening, the engine ECU
electrically operates the E-VRV (for EGR valve control), 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.

Intake Shutter
Intake
Intake Shutter Valve Control Motor
Shutter
Valve Position Valve EGR Valve
Sensor Position Sensor

Vacuum Crankshaft
Vacuum Pump Position Sensor
Damper Accelerator Pedal
Engine Position Sensor
ECU Water Temp.
Sensor
Turbo Pressure
Intake EGR Atmospheric Sensor
Pressure
Manifold Valve Sensor Intake Air
Temp Sensor

E-VRV
Engine (for EGR Valve Control)

Exhaust Manifold
271EG131
 ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-171

16. Diagnosis
D The diagnosis system of the 1KD-FTV and 2KD-FTV engines uses the M-OBD (Multiplex On-Board
Diagnosis).
D When the Engine ECU detects a malfunction, the engine ECU makes a diagnosis and memorizes the failed
section. Furthermore, the check engine warning light in the combination meter illuminates or blinks 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 ECU 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 Engine ECU can output freeze-frame data to the intelligent tester II. This data is stored in the engine EG
ECU at the very moment when the engine ECU has detected its last data of malfunction.
D All the DTCs have been made to correspond to the SAE controlled codes. Some of the DTCs have been
further divided into smaller detection areas than in the past, and new DTCs have been assigned to them.
D For details, see the Hilux Repair Manual.

Service Tip
To clear the DTC that is stored in the engine ECU, use a intelligent tester II or disconnect the battery
terminal or remove the EFI fuse for 1 minute or longer.

17. 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 ECU were to continue to control the engine control system in the normal way. To prevent
such a problem, the fail-safe function of the ECU 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, see the Hilux
Repair Manual.