TOYOTA 1KD/2KD ENGINE COMMON RAIL SYSTEM (CRS)
TOYOTA 1KD/2KD ENGINECOMMON RAIL SYSTEM (CRS)Issued : September 200900400706E
2009 DENSO CORPORATIONAll rights reserved. This material may not be reproducedor copied, in whole or in part, without the writtenpermission of DENSO Corporation.
Table of ContentsTable of ContentsOperation Section1. PRODUCT APPLICATION INFORMATION1.1OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3Applicable Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.4System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52. SUPPLY PUMP2.1Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62.2Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63. RAIL3.1Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84. INJECTOR4.1Change Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94.2Quick Response (QR) Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105. FUEL INJECTION CONTROL5.1Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115.2Injection Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115.3Microinjection Quantity Learning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115.4Wide-Range Cylinder Correction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-136. DIAGNOSTIC TROUBLE CODES (DTC)6.1DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-157. ENGINE ECU7.1LAND CRUISER PRADO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-197.2DYNA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-227.3IMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Operation Section1 11. PRODUCT APPLICATION INFORMATION1.1 OUTLINEMinor changes have been made to the TOYOTA LAND CRUISER, PRADO, DYNA, and IMV. As a result, aportion of the Common Rail System (CRS) equipped with the 1KD-FTV and 2KD-FTV engines haschanged. The construction, operation, and control of main CRS components (supply pump, injectors, rail)are identical to the components described in the previously issued "Common Rail System for TOYOTAHILUX/KIJYANG INNOVA/INNOVA 1KD/2KD (Doc ID: 00400077)". Primary changes and additions arelisted below.The supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type.(refer to P1-6)The rail pressure limiter has been replaced with a pressure discharge valve. (refer to P1-8The injectors have been changed from the G2 type to the G3 type. (refer to P1-9)Microinjection quantity learning control, and wide-range cylinder correction control have been added toinjector control. (refer to P1-11)1.2 Applicable VehiclesVehicle NameLAND CRUISER PRADODYNAIMVEngine TypeEngine Displacement1KD-FTV3.0 L1KD/2KD-FTV3.0 L/2.5 LRemarksAugust 20091.3 Applicable Product ListLAND CRUISER PRADODENSOManufacturerPart NumberPart NumberSupply 0N10AT, 4WD, Europe, Australia, Euro 4275900-046#89661-60N30AT, 4WD, Middle East, General, Euro 3, 2275900-047#89661-60N50AT, 4WD, Middle East, General, Euro 0275900-048#89661-60N20MT, 4WD, Europe, Australia, Euro 4275900-049#89661-60N40MT, 4WD, Middle East, General, Euro 3, 2275900-050#89661-60N60MT, 4WD, Middle East, General, Euro 0131000-155#89871-25010Part NameEngine ECUEDURemarks
Operation SectionPart NameCrankshaft PositionSensorCamshaft PositionSensorAccelerator PedalModuleManifold AbsolutePressure (MAP) SensorCoolant TemperatureSensorIntake Air TemperatureSensorExhaustRecirculation1 2DENSOManufacturerPart NumberPart 5800-30190DENSOManufacturerPart NumberPart Number294000-070#22100-30090SCV: 294200-004#295050-007#23670-30380Different connector, for use with cylinders 1RemarksGas(EGR)ValveDYNAPart NameSupply Pumpand 33030071500-237#89727-60010Engine ECUEDUCrankshaft PositionSensorCamshaft PositionSensorAccelerator PedalModuleMAP SensorCoolant TemperatureSensorIntake Air TemperatureSensorRemarksMT, 2WD, Europe, Euro 4 (C/D), withcharging regulation when startingMT, 2WD, Europe, Euro 4 (C/D), withoutcharging regulation when starting
Operation Section1 3Part NameThrottle PositionSensorEGR ValveDENSOManufacturerPart NumberPart 101397-121#25800-30150DENSOManufacturerPart NumberPart Number294000-094#22100-301201KD, Europe, low lubrication294000-070#22100-300901KD/2KD, ThailandSM294000-090#22100-0L0601KD, Europe, Australia, ThailandSM294000-091#22100-0L0701KD/2KD, Europe, Thailand, India, lowRemarksIMVPart NameSupply PumpRemarkslubricationInjectorRailEngine ECUEngine 001KD, MT, PT-4WD, Europe, Euro 4MA275900-056#89661-0KN201KD, MT, 2WD, Australia, Euro 4MA275900-057#89661-0KN301KD, MT, PT-4WD, Australia, Euro 4MA275900-058#89661-0KN401KD, AT, PT-4WD, Europe, Euro 4MA275900-059#89661-0KN601KD, AT, PT-4WD PRE, Australia, Euro 4MA275900-060#89661-0KN802KD, MT, 2WD, Europe, Euro 4 Class 2MA275900-061#89661-0KP002KD, MT, 2WD, Europe, Euro 4 Class 3MA275900-062#89661-0KP202KD, MT, PT-4WD, Europe, Euro 4MA275900-063#89661-0KP402KD, MT, 2WD PRE, Thailand, Euro 3MA275900-064#89661-0KP502KD, MT, PT-4WD, Thailand, Euro 3RB275900-065#89661-0KN101KD, MT, PT-4WD, Europe, Euro 4RB275900-066#89661-0KN501KD, AT, PT-4WD, Europe, Euro 4RB275900-067#89661-0KN902KD, MT, 2WD, Europe, Euro 4 Class 2RB275900-068#89661-0KP102KD, MT, 2WD, Europe, Euro 4 Class 3RB275900-069#89661-0KP302KD, MT, PT-4WD, Europe, Euro 4HA275900-070#89661-0KN701KD, MT, FT-4WD, India, Euro 71070101310-591#89870-710802KD, MT, 2WD, India, Euro 4 (W/O OBD)
Operation SectionPart NameCrankshaft PositionSensorCamshaft PositionSensorMAP SensorCoolant TemperatureSensorIntake Air TemperatureSensorEGR ValveDENSOManufacturerPart NumberPart 5800-30110101397-116#25800-30120Remarks1 4
1 5Operation Section1.4 System OutlineThe CRS configuration is as per the figure below.
Operation Section1 62. SUPPLY PUMP2.1 Change ItemThe supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type. (Referto [SCV types (SV1, SV2)] on P1-7.)2.2 Suction Control Valve (SCV)The supply pump is equipped with a normally closed type SCV.When the solenoid is energized, the needle valve is pressed upon (in the compact SCV, the cylinder ispulled upon) by the armature, completely opening the fuel passage and supplying fuel to the plunger. (Totalquantity suctionedTotal quantity discharged)When power is removed from the solenoid, the return spring presses the needle valve back to the originalposition, closing the fuel passage.The solenoid is actuated by duty ratio control. Fuel is supplied in an amount corresponding to the opensurface area of the passage, which depends on the duty ratio. The fuel is then discharged by the plungers.
1 7Operation SectionOperational Concept DiagramOperation(1) SCV types (SV1, SV2)The SCV is available in the SV1 type and SV2 type. The SV2 is a compact SCV, while the SV1 is a bitlarger than the SV2.
Operation Section1 83. RAIL3.1 Change ItemBeginning from August 2006 model vehicles, a pressure discharge valve is used in place of the rail pressurelimiter. The engine ECU control and an actuation circuit (EDU) control the pressure discharge valve.
1 9Operation Section4. INJECTOR4.1 Change ItemsThe injectors used with the 1KD-FTV and 2KD-FTV engines have been changed from the G2 type to theG3 type. In comparison to the G2 type injector, the G3 type injector has the following characteristics:The nozzle shape, and shape of the high-pressure seal service have been changed, resulting in a morehigh-pressure resistant structure.The G3 injector is more highly responsive due to changes to the nozzle and solenoid valve.In consideration of the mounting measurements, the overall length for the 295050-008# injector (for usewith cylinders 1 and 2 in the DYNA) has been made shorter by 5.5 mm.
Operation Section1 104.2 Quick Response (QR) CodesQR codes are used to improve the accuracy of the injector injection quantity. The code from the vehicleassembly line is read, then entered into the engine ECU. Similar to the assembly line process, whenperforming service, the ID code is read by a diagnostic tool, and entered into the engine ECU.The injection quantity correction points contained in the injector QR code are shown in the figure below.
1 11Operation Section5. FUEL INJECTION CONTROL5.1 Change ItemMicroinjection quantity learning control, and wide-range cylinder correction control have been added to theCRS equipped with the 1KD-FTV and 2KD-FTV engines.5.2 Injection PatternIn this CRS system, injection occurs a maximum of three times. under normal operations, fuel injectioncontrol is performed with a pilot injection and a main injection. However, an additional pilot injection is addedwhen the engine is started at cold temperatures, as well as when the engine is operating in the lowtemperature, low-rotation speed range.5.3 Microinjection Quantity Learning Control(1) OutlineIn microinjection quantity learning control, the actual injector injection quantity is estimated from thechange in engine rotational speed that accompanies a very small injection. The difference between theestimated actual injection quantity, and the injection quantity command value at that time are learned bythe engine ECU. This difference is then used to correct the actual injection quantity.(2) GoalMicroinjection quantity learning control is used to accomplish the following: 1) to minimize injectionquantity deviations due to injector deterioration over time, and 2) to prevent both engine running noisedue to misfires and exhaust smoke.(3) Control outlineMicroinjection quantity learning control is automatically performed approximately every 2000 km ofnormal vehicle operation, and is completed after the vehicle has traveled approximately 500 km. Actuallearning takes place during the following processes.
Operation Section1 12Determination for learning conditionsMicroinjection quantity learning control is performed when the following two engine operations areestablished: 1) a reduction in vehicle speed, and 2) injection is cut off. In the determination process, theengine ECU then judges whether or not the conditions for learning have been met. The figure belowshows the specific details for learning determinations.Single microinjection operationUnder the single microinjection operation process, microinjection is performed once the following itemsare set: 1) the cylinder for which learning will be performed, and 2) the injection quantity. The figurebelow shows the specific settings and controls for a single microinjection.Detecting the change in rotational speed via injectionIn this process, the change in rotational speed can be detected using the set microinjection. The figurebelow shows the processing for calculating changes in rotational speed.
1 13Operation SectionCorrecting the injection pulse width (TQ), and actual injection quantity (Q) characteristicsIn this process, the actual injection quantity is estimated from the set microinjection, and the change inrotational speed. The actual injection quantity is then corrected such that the value equals the targetinjection quantity. The figure below shows the processing for the aforementioned corrections.[ REFERENCE ]Learning must be performed manually when either an injector (or injectors), or the engine ECU is replaced.As per the figure below, diagnostic tools are used to perform learning while the engine is operating.5.4 Wide-Range Cylinder Correction Control(1) OutlineIn wide-range cylinder correction control, the combustion state for each cylinder is detected based on thecrankshaft position sensor (NE) signal. The injection quantity across all the cylinders can then beaveraged by correcting the injection quantity for each injector. Wide-range cylinder correction controlcorrects the conventional FCCB control (idle speed stabilization control) performed at idle speed in allregions of rotation.
Operation Section1 14(2) Control outlineThe difference between the final injection quantity and the actual injection quantity are learned based onthe loop in the figure below. Next, the following two items are compared: 1) the results of the actualinjection quantity estimate based on the ideal state for NE input, and 2) the results of the actual injectionquantity estimate based on the actual NE input (detected value.)Finally, the optimal emission state is found as shown in the figure below.The correction below shows pilot injection 2 and main injection.
1 15Operation Section6. DIAGNOSTIC TROUBLE CODES (DTC)6.1 DTC TableDTCMalfunctionSAE CodeDetection ItemIndicator Lamp(MIL)P00AFYesVariable Nozzle Turbo (VNT) Driver Abnormality, Position RequestSignal AbnormalityP0046YesVNT Nozzle Sliding AbnormalityP0047YesVNT Motor Circuit OpenP0048YesVNT Motor Circuit ShortP0069YesPressure Difference Abnormality Between Boost Pressure andAtmospheric PressureP0087YesRail Pressure Sensor AbnormalityP0088YesPressure Discharge Valve AbnormalityP0093YesFuel LeakP0095YesIntake Air Temperature Sensor System AbnormalityP0097YesIntake Air Temperature Sensor LowP0098YesIntake Air Temperature Sensor HighP0101YesMass Air Flow (MAF) Meter Out of RangeP0102YesMAF Meter LowP0103YesMAF Meter HighP0105YesManifold Absolute Pressure (MAP) Sensor System AbnormalityP0106YesMAP Sensor Out of RangeP0107YesMAP Sensor LowP0108YesMAP Sensor HighP0110YesIntake Air Temperature Sensor System AbnormalityP0112YesIntake Air Temperature Sensor LowP0113YesIntake Air Temperature Sensor HighP0115YesCoolant Temperature Sensor System AbnormalityP0116YesCoolant Temperature Sensor Circuit Range/PerformanceP0117YesCoolant Temperature Sensor LowP0118YesCoolant Temperature Sensor HighP0122YesDiesel Throttle Position Sensor LowP0123YesDiesel Throttle Position Sensor HighP0168YesHigh Fuel Temperature AbnormalityP0180YesFuel Temperature Sensor System Abnormality
Operation SectionDTCMalfunctionSAE CodeDetection ItemIndicator Lamp(MIL)P0182YesFuel Temperature Sensor LowP0183YesFuel Temperature Sensor HighP0190YesRail Pressure Sensor System AbnormalityP0191YesRail Pressure Sensor Characteristics AbnormalityP0192YesRail Pressure Sensor LowP0193YesRail Pressure Sensor HighP0200YesEDU Circuit AbnormalityP0299YesVNT Closed AbnormalityP0335YesCrankshaft Position Sensor AbnormalityP0339NoCrankshaft Position Sensor Power FlickerP0340YesCamshaft Position Sensor Open CircuitP0400YesExhaust Gas Recirculation (EGR) Flow Volume AbnormalityP0405YesEGR Lift Sensor LowP0406YesEGR Lift Sensor HighP0488YesEGR Throttle Motor System AbnormalityP0489YesEGR E-VRV LowP0490YesEGR E-VRV HighP0500YesVehicle Speed Sensor System AbnormalityVehicle Speed Sensor Power Flicker NoiseP0503P0504NoStop Lamp Switch System AbnormalityP0516Battery Temperature Sensor LowP0517Battery Temperature Sensor HighP0560YesBattery AbnormalityP0571Stop Lamp Switch (Open, Short)P0575Cruise Cancel Circuit AbnormalityP0606YesEngine ECU Internal AbnormalityP0607YesControl Module PerformanceP060AYesEngine ECU Monitor CPU AbnormalityP060BYesEngine ECU Peripheral Circuit AbnormalityP0617YesStarter Circuit HighP0627YesSupply Pump SCV Abnormality (Open, ShortÅjP0724YesStop Lamp Switch AbnormalityP1229YesSupply Pump Abnormality (Overfeed)P1238YesInjector Injection AbnormalityP1251YesVNT Abnormality (Power Flicker)P1264YesVNT Driver Abnormality1 16
1 17Operation SectionDTCMalfunctionSAE CodeDetection ItemIndicator Lamp(MIL)P1271YesPressure Discharge Valve System AbnormalityP1272YesPressure Discharge Valve (Stuck Closed)P1496YesIntake Air Temperature Sensor LowP1497YesIntake Air Temperature Sensor HighP1550Battery Current Sensor AbnormalityP1551Battery Current Sensor LowP1552Battery Current Sensor HighP1570Laser Sensor AbnormalityP1572Laser Sensor Optical Axis MisalignmentP1575Warning Buzzer AbnormalityP1578Brake System AbnormalityP1601YesP1602Injector ID Code Abnormality, UnregisteredBattery Low VoltageP1604NoPoor Start JudgmentP1605NoUnstable IdleP1607YesCruise Control CPU AbnormalityP1611YesInternal IC AbnormalityP1615DSS1 ECU Communication AbnormalityP1616Vehicle Control ECU Communication AbnormalityP1617Vehicle Control ECU AbnormalityP1630VSCENG Communication Abnormality (VSCENG)P1631VSCENG Communication Abnormality (ENGVSC)P2006YesSwirl Control Valve Stuck Fully Closed AbnormalityP2009YesSwirl Control Valve VSV Abnormality - LowP2010YesSwirl Control Valve VSV Abnormality - HighP2120YesAccelerator Position Sensor No. 1 (Open)P2121YesAccelerator Position Sensor (Out of Range)P2122YesAccelerator Position Sensor No. 1 (Open) LowP2123YesAccelerator Position Sensor No. 1 (Open) HighP2125YesAccelerator Position Sensor No. 2 (Open)P2127YesAccelerator Position Sensor No. 2 (Open) LowP2128YesAccelerator Position Sensor No. 2 (Open) HighP2138YesAccelerator Position Sensor No. 1/ No. 2 OpenP2226YesAtmospheric Pressure Sensor (Open)P2228YesAtmospheric Pressure Sensor LowP2229YesAtmospheric Pressure Sensor High
Operation Section1 18DTCMalfunctionSAE CodeDetection ItemIndicator Lamp(MIL)P245CYesEGR Cooler Bypass Actuation VSV LowP245DYesEGR Cooler Bypass Actuation VSV HighP2501Alternator AbnormalityP2563YesVNT Position Sensor Characteristics DiscrepancyP2564YesVNT Position Sensor 1 OpenP2565YesVNT Position Sensor 1 ShortP2588YesVNT Position Sensor 2 OpenP2589YesVNT Position Sensor 2 ShortU0100U0101Vehicle Control ECU Communication AbnormalityYesTCM ECU CAN Communication AbnormalityU0122VSCENG Communication Abnormality (VSCENG)U0123Yaw Rate Sensor Communication AbnormalityU0126Steering Sensor Communication AbnormalityU0235Laser Se
The nozzle shape, and shape of the high-pressure seal service have been changed, resulting in a more high-pressure resistant structure. The G3 injector is more highly responsive due to changes to the nozzle and solenoid valve. In consideration of the mounting measurements, the overall length for the 295050-008# injector (for use
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The New Hilux / Kijang Innova uses D-4D 2nd generation common-rail Diesel engines that are 3.0-liter, 1KD-FTV engine and 2.5-l\൩ter, 2KD-FTV engine.\爀屮D-4D means Direct Injection 4-stroke common-rail Diesel and the newer designed common-rail is called “D-對4D 2nd Generation common-rail”\爀屮This is a combination of Direct injection .
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