Toyota 1kd2kd Common Rail System

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TOYOTA 1KD/2KD ENGINE

COMMON RAIL SYSTEM (CRS)
Issued : September 2009

Revised : October 2009
00400706EA
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Revision History
Date Revision Contents
2009.10 • Visual contents addition
Visual contents are video and animation used for manual explanation. Visual con-
tents can be viewed by clicking the appropriate button.
• Items added to the visual contents
The following items have been added to “Microinjection Quantity Learning Control“
under “FUEL INJECTION CONTROL".
 Determinations for learning conditions
 Single microinjection operation
 Detecting the change in rotational speed via injection
 Correcting the injection pulse width (TQ), and actual injection quantity (Q) char-
acteristics
©
2009 DENSO CORPORATION
All rights reserved. This material may not be reproduced
or copied, in whole or in part, without the written
permission of DENSO Corporation.
Table of Contents
Table of Contents
Operation Section
1. PRODUCT APPLICATION INFORMATION

1.1 OUTLINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Applicable Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2. SUPPLY PUMP
2.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2.2 Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3. RAIL
3.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
4. INJECTOR
4.1 Change Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
4.2 Quick Response (QR) Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
5. FUEL INJECTION CONTROL

5.1 Change Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5.2 Injection Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5.3 Microinjection Quantity Learning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5.4 Wide-Range Cylinder Correction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
6. DIAGNOSTIC TROUBLE CODES (DTC)

6.1 DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
7. ENGINE ECU
7.1 LAND CRUISER PRADO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
7.2 DYNA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
7.3 IMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Operation Section
1 – 1
1. PRODUCT APPLICATION INFORMATION
1.1 OUTLINE
 Minor changes have been made to the TOYOTA LAND CRUISER, PRADO, DYNA, and IMV. As a result, a
portion of the Common Rail System (CRS) equipped with the 1KD-FTV and 2KD-FTV engines has
changed. 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 TOYOTA
HILUX/KIJYANG INNOVA/INNOVA 1KD/2KD (Doc ID: 00400077)". Primary changes and additions are
listed 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 P1-8)
• The 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 to
injector control. (refer to P1-11)
1.2 Applicable Vehicles
Vehicle Name Engine Type Engine Displacement Remarks

LAND CRUISER PRADO
1KD-FTV 3.0 L
DYNA August 2009
IMV 1KD/2KD-FTV 3.0 L/2.5 L
1.3 Applicable Product List

LAND CRUISER PRADO
DENSO Manufacturer
Part Name Remarks
Part Number Part Number
Supply Pump 294000-110# 22100-30140
Injector 295050-020# 23670-30400
Rail 095440-095# 23810-30100
275900-045# 89661-60N10 AT, 4WD, Europe, Australia, Euro 4
275900-046# 89661-60N30 AT, 4WD, Middle East, General, Euro 3, 2
275900-047# 89661-60N50 AT, 4WD, Middle East, General, Euro 0
Engine ECU
275900-048# 89661-60N20 MT, 4WD, Europe, Australia, Euro 4
275900-049# 89661-60N40 MT, 4WD, Middle East, General, Euro 3, 2
275900-050# 89661-60N60 MT, 4WD, Middle East, General, Euro 0
EDU 131000-155# 89871-25010
Operation Section
1 – 2
DENSO Manufacturer
Part Name Remarks
Crankshaft Position
029600-143# 90919-05066
Sensor
Camshaft Position
029600-116# 90919-05052
Sensor
Accelerator Pedal
198800-742# 78110-60030
Module
Manifold Absolute
079800-780# 89421-20200
Pressure (MAP) Sensor
Coolant Temperature
179700-045# 89422-33030
Sensor
Intake Air Temperature
Sensor 071500-237# 89727-60010
Exhaust Gas
Recirculation (EGR) 101397-123# 25800-30190
Valve
DYNA
DENSO Manufacturer
Part Name Remarks
Supply Pump 294000-070# 22100-30090 SCV: 294200-004#
295050-007# 23670-30380 Different connector, for use with cylinders 1

Injector and 2
295050-008# 23670-30390
Rail 095440-095# 23810-30100
MT, 2WD, Europe, Euro 4 (C/D), with
275900-053# 89661-25290
charging regulation when starting
Engine ECU
MT, 2WD, Europe, Euro 4 (C/D), without
275900-054# 89661-25300
charging regulation when starting
101310-570# 89870-25030
EDU 101310-581# 89870-25040
Crankshaft Position
029600-143# 90919-05066
Sensor
Camshaft Position
029600-116# 90919-05052
Sensor
Accelerator Pedal
198300-302# 89281-35020
Module
MAP Sensor 079800-780# 89421-20200
Coolant Temperature
Sensor 179700-045# 89422-33030
071500-237# 89727-60010
Sensor
Operation Section
1 – 3
DENSO Manufacturer
Part Name Remarks
Throttle Position
192300-201# 15081-3F00B
Sensor
101397-118# 25800-30140
EGR Valve
101397-121# 25800-30150
IMV
DENSO Manufacturer
Part Name Remarks
294000-094# 22100-30120 1KD, Europe, low lubrication
294000-070# 22100-30090 1KD/2KD, Thailand
Supply Pump SM294000-090# 22100-0L060 1KD, Europe, Australia, Thailand
SM294000-091# 22100-0L070 1KD/2KD, Europe, Thailand, India, low
lubrication
295050-020# 23670-30400 1KD/2KD
295050-021# 23670-30410 2KD
Injector
SM295050-018# 23670-0L090 1KD/2KD
SM295050-019# 23670-0L100 2KD
095440-095# 23810-30100 1KD/2KD
Rail
SM095440-095# 23810-0L030 1KD/2KD
MA275900-055# 89661-0KN00 1KD, MT, PT-4WD, Europe, Euro 4

MA275900-056# 89661-0KN20 1KD, MT, 2WD, Australia, Euro 4
MA275900-057# 89661-0KN30 1KD, MT, PT-4WD, Australia, Euro 4
MA275900-058# 89661-0KN40 1KD, AT, PT-4WD, Europe, Euro 4
MA275900-059# 89661-0KN60 1KD, AT, PT-4WD PRE, Australia, Euro 4
MA275900-060# 89661-0KN80 2KD, MT, 2WD, Europe, Euro 4 Class 2
MA275900-061# 89661-0KP00 2KD, MT, 2WD, Europe, Euro 4 Class 3
Engine ECU
MA275900-062# 89661-0KP20 2KD, MT, PT-4WD, Europe, Euro 4
MA275900-063# 89661-0KP40 2KD, MT, 2WD PRE, Thailand, Euro 3
MA275900-064# 89661-0KP50 2KD, MT, PT-4WD, Thailand, Euro 3
RB275900-065# 89661-0KN10 1KD, MT, PT-4WD, Europe, Euro 4
RB275900-066# 89661-0KN50 1KD, AT, PT-4WD, Europe, Euro 4
RB275900-067# 89661-0KN90 2KD, MT, 2WD, Europe, Euro 4 Class 2
RB275900-068# 89661-0KP10 2KD, MT, 2WD, Europe, Euro 4 Class 3
RB275900-069# 89661-0KP30 2KD, MT, PT-4WD, Europe, Euro 4
HA275900-070# 89661-0KN70 1KD, MT, FT-4WD, India, Euro 4(W/O
Engine ECU
OBD)
HA275900-071# 89661-0KP60 2KD, MT, 2WD, India, Euro 4 (W/O OBD)
101310-590# 89870-71070
EDU
101310-591# 89870-71080
Operation Section
1 – 4
DENSO Manufacturer
Part Name Remarks
Crankshaft Position
029600-063# 90919-05025
Sensor
Camshaft Position
029600-115# 90919-05050
Sensor
MAP Sensor 079800-913# 89421-20200
Coolant Temperature
179700-045# 89421-71030
Sensor
170400-602# 89424-12010
Sensor
101397-113# 25800-30100
EGR Valve 101397-114# 25800-30110
101397-116# 25800-30120
Operation Section
1 – 5
1.4 System Outline

 The CRS configuration is as per the figure below.
EGR Cooler
EGR Valve
Engine
EDU
ECU
Injector
Variable Nozzle
Turbo
Rail
Pressure Diesel
Discharge Throttle
Valve
Fuel Fuel
Supply Pump
Filter Cooler
Fuel Tank
Q004457E
Operation Section
1 – 6
2. SUPPLY PUMP
2.1 Change Item

 The supply pump Suction Control Valve (SCV) has been changed from the SV2 type to the SV1 type. (Refer
to [SCV types (SV1, SV2)] on P1-7.)
to Fuel Tank to Fuel Tank
to Rail
from
Fuel Tank
SCV
Fuel Temperature Fuel Temperature
Sensor Sensor
Q004458E
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 is
pulled upon) by the armature, completely opening the fuel passage and supplying fuel to the plunger. (Total
quantity suctioned → Total quantity discharged)
 When power is removed from the solenoid, the return spring presses the needle valve back to the original
position, closing the fuel passage.
 The solenoid is actuated by duty ratio control. Fuel is supplied in an amount corresponding to the open
surface area of the passage, which depends on the duty ratio. The fuel is then discharged by the plungers.
Needle Valve Armature
Return Spring
Valve Body Solenoid

Q004459E
Operation Section
1 – 7
Feed Pump
Plunger
Cylinder
Supply Pump
SCV
Q002505E
Operational Concept Diagram
Short Duty ON Long Duty ON

Small Valve Opening Large Valve Opening
Minimum Intake Quantity Maximum Intake Quantity
Cylinder Small Opening Cylinder Large Opening
Q004460E
Operation
(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 bit
larger than the SV2.
SV1 Type SCV SV2 Type SCV
Q003726E
Operation Section
1 – 8
3. RAIL
3.1 Change Item

 Beginning from August 2006 model vehicles, a pressure discharge valve is used in place of the rail pressure
limiter. The engine ECU control and an actuation circuit (EDU) control the pressure discharge valve.
Rail Pressure Sensor Pressure Discharge Valve
Q004461E
Operation Section
1 – 9
4. INJECTOR
4.1 Change Items

 The injectors used with the 1KD-FTV and 2KD-FTV engines have been changed from the G2 type to the
G3 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 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
with cylinders 1 and 2 in the DYNA) has been made shorter by 5.5 mm.
295050-007# SM295050-018# 295050-008#

295050-020# SM295050-019#
295050-021#
http://slidepdf.com/reader/full/toyota-1kd2kd-common-rail-system Q004462E 12/31

Operation Section
1 – 10
4.2 Quick Response (QR) Codes

 QR codes are used to improve the accuracy of the injector injection quantity. The code from the vehicle
assembly line is read, then entered into the engine ECU. Similar to the assembly line process, when
performing service, the ID code is read by a diagnostic tool, and entered into the engine ECU.
QR Codes ( 9.9 mm) QR Codes ( 9.9 mm)
ID Codes (30 Base-16 Characters) ID Codes (30 Base-16 Characters)

Base-16 characters noting fuel injection Base-S16 characters noting fuel injection
quantity correction information for market quantity correction information for market
service use. service use.
295050-007# SM295050-018# 295050-008#

295050-020# SM295050-019#
295050-021#
Q004463E
 The injection quantity correction points contained in the injector QR code are shown in the figure below.
180 MPa 140 MPa

Q 100 MPa
y
t
i
t Correction
n
a 64 MPa
12 Points
u
Q
n
o
i 32 MPa
t
c
e
j
n
I
Actuating Pulse Width TQ

Q004464E
Operation Section
1 – 11
5. FUEL INJECTION CONTROL
5.1 Change Item

 Microinjection quantity learning control, and wide-range cylinder correction control have been added to the
CRS equipped with the 1KD-FTV and 2KD-FTV engines.
5.2 Injection Pattern

 In this CRS system, injection occurs a maximum of three times. under normal operations, fuel injection
control is performed with a pilot injection and a main injection. However, an additional pilot injection is added
when the engine is started at cold temperatures, as well as when the engine is operating in the low-
temperature, low-rotation speed range.
Main Injection
TDC
Pilot Injection 1 Pilot Injection 2
Note) TOYOTA terminology is used in this Q004465E

figure.
5.3 Microinjection Quantity Learning Control
(1) Outline
• In microinjection quantity learning control, the actual injector injection quantity is estimated from the
change in engine rotational speed that accompanies a very small injection. The difference between the
estimated actual injection quantity, and the injection quantity command value at that time are learned by
the engine ECU. This difference is then used to correct the actual injection quantity.
(2) Goal
• Microinjection quantity learning control is used to accomplish the following: 1) to minimize injection
quantity deviations due to injector deterioration over time, and 2) to prevent both engine running noise
due to misfires and exhaust smoke.
(3) Control outline
• Microinjection quantity learning control is automatically performed approximately every 2000 km of
normal vehicle operation, and is completed after the vehicle has traveled approximately 500 km. Actual
learning takes place during the following processes.
Operation Section
1 – 12
Determination for learning conditions

 Microinjection quantity learning control is performed when the following two engine operations are
established: 1) a reduction in vehicle speed, and 2) injection is cut off. In the determination process, the
engine ECU then judges whether or not the conditions for learning have been met. The figure below
shows the specific details for learning determinations.
Engine Rotational Speed

Determination Content
Non-injection determination Injection
Quantity Q
Deceleration determination
Clutch position determination
*For manual transmission vehicles Q=0
Determination
Time
Q002593E
Single microinjection operation

 Under the single microinjection operation process, microinjection is performed once the following items
are set: 1) the cylinder for which learning will be performed, and 2) the injection quantity. The figure
below shows the specific settings and controls for a single microinjection.
Rail Pressure
Settings, Control, Injection
Injection
Injection cylinder setting Quantity Q
Command injection quantity setting
Injection timing setting
Injection pressure (rail pressure) setting, control Q=0
Fuel injection
Injection Time
Q002594E
Detecting the change in rotational speed via injection

 In this process, the change in rotational speed can be detected using the set microinjection. The figure
below shows the processing for calculating changes in rotational speed.
Engine Rotational Speed

Detection
ete tion
Injection
Processing Quantity Q
Rotational speed change detection
Rotational speed change processing
Q=0
Injection Time
Q002595E
Operation Section
1 – 13
Correcting the injection pulse width (TQ), and actual injection quantity (Q) characteristics
 In this process, the actual injection quantity is estimated from the set microinjection, and the change in
rotational speed. The actual injection quantity is then corrected such that the value equals the target
injection quantity. The figure below shows the processing for the aforementioned corrections.
Q Map Value Actual Injection

Quantity
Processing Target Q
Estimation of correction quantity from each
detected value
Reflection of correction quantity
Injection Pulse Width TQ

Q002596E
[ 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.
No Load 3000 - 4000 rpm Non-Injection Learning

(Approximately 10 Single Injections)
Rail Pressure Adjusting

Idle During this Interval Injection Recovery Idle
Approximately
1 sec. Approximately 3 sec. 2 sec. 1 sec.
Unit Cycle Approximately 7 sec.
Q002597E
5.4 Wide-Range Cylinder Correction Control
(1) Outline
• In wide-range cylinder correction control, the combustion state for each cylinder is detected based on the
crankshaft position sensor (NE) signal. The injection quantity across all the cylinders can then be
averaged by correcting the injection quantity for each injector. Wide-range cylinder correction control
corrects the conventional FCCB control (idle speed stabilization control) performed at idle speed in all
regions of rotation.
Operation Section
1 – 14
(2) Control outline
• The difference between the final injection quantity and the actual injection quantity are learned based on
the loop in the figure below. Next, the following two items are compared: 1) the results of the actual
injection quantity estimate based on the ideal state for NE input, and 2) the results of the actual injection
quantity estimate based on the actual NE input (detected value.)
Difference Between Both Values Learned
Command Actual Injection Actual Rotational

Command Output
Injection Quantity Quantity Speed
Wide-Range Injection Rotational

Quantity Learning Speed Output
Q002598E
• Finally, the optimal emission state is found as shown in the figure below.
Includes Error from Compatible Vehicle
Actual
Optimal Command Actual Rotational Optimal Emissions
Command Output Injection Speed (Optimal Exhaust Gas)
Injection Quantity
Quantity
Ideal Rotational Rotational Speed

Speed Detection
Target Value
Q002599E
• The correction below shows pilot injection 2 and main injection.
Main Injection
Pilot Injection 1 Pilot Injection 2
The total deviation in injection quantity is learned via wide-range injection quantity learning.
: Reflected in the main injection quantity
Q004484E
Operation Section
1 – 15
6. DIAGNOSTIC TROUBLE CODES (DTC)
6.1 DTC Table

DTC
Malfunction
Detection Item
SAE Code Indicator Lamp
(MIL)
P00AF Yes Variable Nozzle Turbo (VNT) Driver Abnormality, Position Request
Signal Abnormality
P0046 Yes VNT Nozzle Sliding Abnormality
P0047 Yes VNT Motor Circuit Open
P0048 Yes VNT Motor Circuit Short
P0069 Yes Pressure Difference Abnormality Between Boost Pressure and
Atmospheric Pressure
P0087 Yes Rail Pressure Sensor Abnormality
P0088 Yes Pressure Discharge Valve Abnormality
P0093 Yes Fuel Leak
P0095 Yes Intake Air Temperature Sensor System Abnormality
P0097 Yes Intake Air Temperature Sensor Low

P0098 Yes Intake Air Temperature Sensor High
P0101 Yes Mass Air Flow (MAF) Meter Out of Range
P0102 Yes MAF Meter Low
P0103 Yes MAF Meter High
P0105 Yes Manifold Absolute Pressure (MAP) Sensor System Abnormality
P0106 Yes MAP Sensor Out of Range
P0107 Yes MAP Sensor Low
P0108 Yes MAP Sensor High
P0110 Yes Intake Air Temperature Sensor System Abnormality
P0115 Yes Coolant Temperature Sensor System Abnormality
P0116 Yes Coolant Temperature Sensor Circuit Range/Performance
P0117 Yes Coolant Temperature Sensor Low
P0118 Yes Coolant Temperature Sensor High
P0122 Yes Diesel Throttle Position Sensor Low
P0123 Yes Diesel Throttle Position Sensor High
P0168 Yes High Fuel Temperature Abnormality
P0180 Yes Fuel Temperature Sensor System Abnormality
Operation Section
1 – 16
DTC
Malfunction
Detection Item
(MIL)
P0182 Yes Fuel Temperature Sensor Low
P0183 Yes Fuel Temperature Sensor High
P0190 Yes Rail Pressure Sensor System Abnormality
P0191 Yes Rail Pressure Sensor Characteristics Abnormality
P0192 Yes Rail Pressure Sensor Low
P0193 Yes Rail Pressure Sensor High
P0200 Yes EDU Circuit Abnormality
P0299 Yes VNT Closed Abnormality
P0335 Yes Crankshaft Position Sensor Abnormality
P0339 No Crankshaft Position Sensor Power Flicker
P0340 Yes Camshaft Position Sensor Open Circuit
P0400 Yes Exhaust Gas Recirculation (EGR) Flow Volume Abnormality
P0405 Yes EGR Lift Sensor Low
P0406 Yes EGR Lift Sensor High
P0488 Yes EGR Throttle Motor System Abnormality
P0489 Yes EGR E-VRV Low
P0490 Yes EGR E-VRV High

P0500 Yes Vehicle Speed Sensor System Abnormality
P0503 － Vehicle Speed Sensor Power Flicker Noise
P0504 No Stop Lamp Switch System Abnormality
P0516 － Battery Temperature Sensor Low
P0517 － Battery Temperature Sensor High
P0560 Yes Battery Abnormality
P0571 － Stop Lamp Switch (Open, Short)
－
P0575 Cruise Cancel Circuit Abnormality
P0606 Yes Engine ECU Internal Abnormality
P0607 Yes Control Module Performance
P060A Yes Engine ECU Monitor CPU Abnormality
P060B Yes Engine ECU Peripheral Circuit Abnormality
P0617 Yes Starter Circuit High
P0627 Yes Supply Pump SCV Abnormality (Open, ShortÅj
P0724 Yes Stop Lamp Switch Abnormality
P1229 Yes Supply Pump Abnormality (Overfeed)
P1238 Yes Injector Injection Abnormality
P1251 Yes VNT Abnormality (Power Flicker)
P1264 Yes VNT Driver Abnormality
Operation Section
1 – 17
DTC
Malfunction
Detection Item
(MIL)
P1271 Yes Pressure Discharge Valve System Abnormality
P1272 Yes Pressure Discharge Valve (Stuck Closed)
P1550 － Battery Current Sensor Abnormality
P1551 － Battery Current Sensor Low
P1552 － Battery Current Sensor High
P1570 － Laser Sensor Abnormality
P1572 － Laser Sensor Optical Axis Misalignment
P1575 － Warning Buzzer Abnormality
P1578 － Brake System Abnormality
P1601 Yes Injector ID Code Abnormality, Unregistered
P1602 － Battery Low Voltage
P1604 No Poor Start Judgment
P1605 No Unstable Idle
P1607 Yes Cruise Control CPU Abnormality
P1611 Yes Internal IC Abnormality

P1615 － DSS1 ECU Communication Abnormality
P1616 － Vehicle Control ECU Communication Abnormality
P1617 － Vehicle Control ECU Abnormality
P1630 － VSC ↔ ENG Communication Abnormality (VSC → ENG)
P1631 － VSC ↔ ENG Communication Abnormality (ENG → VSC)
P2006 Yes Swirl Control Valve Stuck Fully Closed Abnormality
P2009 Yes Swirl Control Valve VSV Abnormality - Low
P2010 Yes Swirl Control Valve VSV Abnormality - High

P2120 Yes Accelerator Position Sensor No. 1 (Open)
P2121 Yes Accelerator Position Sensor (Out of Range)
P2122 Yes Accelerator Position Sensor No. 1 (Open) Low
P2123 Yes Accelerator Position Sensor No. 1 (Open) High
P2125 Yes Accelerator Position Sensor No. 2 (Open)
P2127 Yes Accelerator Position Sensor No. 2 (Open) Low
P2128 Yes Accelerator Position Sensor No. 2 (Open) High
P2138 Yes Accelerator Position Sensor No. 1/ No. 2 Open
P2226 Yes Atmospheric Pressure Sensor (Open)
P2228 Yes Atmospheric Pressure Sensor Low
P2229 Yes Atmospheric Pressure Sensor High
Operation Section
1 – 18
DTC
Malfunction
Detection Item
(MIL)
P245C Yes EGR Cooler Bypass Actuation VSV Low
P245D Yes EGR Cooler Bypass Actuation VSV High
P2501 － Alternator Abnormality
P2563 Yes VNT Position Sensor Characteristics Discrepancy
P2564 Yes VNT Position Sensor 1 Open
P2565 Yes VNT Position Sensor 1 Short
P2588 Yes VNT Position Sensor 2 Open
P2589 Yes VNT Position Sensor 2 Short
U0100 － Vehicle Control ECU Communication Abnormality
U0101 Yes TCM ECU CAN Communication Abnormality
U0122 － VSC ↔ ENG Communication Abnormality (VSC → ENG)
U0123 － Yaw Rate Sensor Communication Abnormality
U0126 － Steering Sensor Communication Abnormality
U0235 － Laser Sensor Communication Abnormality (Sensor → Vehicle ECU)
U1102 － Laser Sensor Communication Abnormality (Vehicle ECU → Sensor)
U1104 － DSS1 ECU Communication Abnormality
Operation Section
1 – 19
7. ENGINE ECU
7.1 LAND CRUISER PRADO
Main Relay
15A 140 +B
Fuse-EFI 143 +B2
MREL PCV+ 6 PCV (Suction Control Valve) (2.1 )
139 BATT
PCV- 12
12V 13 E1
2 E01 LUSL 41
3 E02 Rotary Solenoid Driver
9 ME01
Engine Earth ALT 31
Engine Earth Alternator
OBDII Check 109 WFSE
Connector W 105 MIL
135 VCPA IG2
Accelerator Position Sensor 137 VPA
(Main) 134 EPA IREL 127
+B
133 VCP2 EDU Relay
Accelerator Position Sensor 136 VPA2 GREL 27 BATT
(Sub) 132 EPA2 Glow Plug Relay
65 VNVC
VNT Position Sensor 83 VNA ACT 114
64 VNE2 AC1 125 A/C ECU
44 VCEG
EGR Lift Sensor 81 EGLS Circuit Opening
FC 129
45 EEGL Relay
66 VCPM MREL 126 Main Relay M

MAP Sensor 82 PIM Fuel Pump
47 EPIM
62 VCVL #4 38
Diesel Throttle Position Sensor 80 VLU1 #3 37
63 EVLU #2 36
51 VCS1 EDU
#1 35
Rail Pressure Sensor 53 PCR1
PRD 33
(Main) 52 E2S1
50 VCS2 NEO 130 Power Supply
Rail Pressure Sensor 85 PCR2 Management ECU +B
+B
(Sub) 68 E2S2
SCV 14
MAF 54 VG
Swirl Contr ol Valve
Meter 55 E2G (29 at 20 )
SCV2 15
Intake Air Temperature Sensor 86 THIA
Swirl Control Valve 2
(Intake Manifold) 69 ETHI (29 at 20 )
ECBV 16
Fuel Temperature Sensor 87 THF EGR Cooler Bypass VSV
70 ETHF EGR 10 (29.7 at 20 )
Coolant Temperature Sensor 88 THW E-VRV (12 at 20 
71 ETHW EGRC 58
Intake Air Temperature Sensor 89 THA EGR Cut VSV (36 at 20 )
(built into MAF Meter) ACM 144
72 ETHA
VSV
Q004466E
Engine ECU External Wiring Diagrams (1)
Operation Section
1 – 20
Cruise Control Switch

113 CCS
e 124 CCHG

l e
l
e m c
i
c u n e
h t
n t s i e a
a e e a V
- R With 275900-045#,
o t
C S R M t l
- t
e
l n
a o
r
-046#, -047#
c s t
i
h n n
e o o
V C C
Shield
VNM+ 7
Shield 56 NE+
Crankshaft Position Sensor VNT DC Motor
39 G+
VNM- 8
Shield 57 NE-
Camshaft Position Sensor 40 GND 11
G-
IG2
Brake Switch Engine Earth 121 ST1- With 275900-045#, -046#, -047#
120 STP
BATT
IGSW 111 IGSW CAN+ 19
ECT ECU
Stop Lamp Relay CAN- 22
With 275900-048#, -049#, -050#

Backup Lamp Switch (M/T)
48 R CANH 94
IG1
Clutch Switch (M/T) CANL 95 Vehicle Bus
46 CLSW
IG2
CANP 96
With 275900-045#, -046#, -047# Power Supply
CANN 97 Management ECU
46 D
GAUSE
Neutral Start Switch(AT)
IMI 101
PS Hydraulic Switch 24 PSW ID Code
IMO 102
With 275900-048#, -049#, -050# Box
98 L4 EC 145
4WD ECU
Body Earth
EOM 118
With 275900-045#, -046#, -047#
100 LGND
Radar Sensor
EDU
34 INJ1
Vehicle Speed Sensor IG
103 SPD
FANL 138
With 275900-045#, -046#, -047# Fan Relay
Neutral Start Switch (AT)
21 NSW
Starter Relay 128 STA

110 TC
DLC3 104 TACH
Q004467E
Operation Section
1 – 21
90 91 92 93 94 95 96 97 138 139 140

19 20 21 98 99 100101102103 104105
1 2 3 4 5 6 2 2 23 2 4 25 2 6 27 2 8 29 30 3 1 32 33 34 3 5 36 37 38 106107108109 110111 112113 141 142 143
7 8 9 10 11 12 3 9 40 4 1 42 4 3 44 4 5 46 47 4 8 49 50 51 5 2 53 54 55 114115116117 118119 120121 144 145 146

5 6 57 5 8 59 6 0 61 6 2 63 64 6 5 66 67 68 6 9 70 71 72 122123124125126127 128129
13 14 15 16 17 18 7 3 74 7 5 76 7 7 78 7 9 80 81 8 2 83 84 85 8 6 87 88 89 130131132133134135 136137 147 148 149
Q002653
Engine ECU Connector Terminal Layout
Operation Section
1 – 22
7.2 DYNA
Main Relay 140

15A +B
Fuse-EFI
MREL PCV+ 6 PCV (Suction Control Valve) (2.1 )
139 BATT PCV- 12
12V 13 E1
2 E01 LUSL 41
Rotary Solenoid Driver
3 E02
Engine Earth
OBDII Check 109 WFSE

Connector
135 VCPA
Accelerator Position Sensor (Main)
VNTO 25
137 VPA
134 EPA VNTI 26 VNT Driver
133 VCP2
Accelerator Position Sensor (Sub)
136 VPA2
132 EPA2 ALT 31
44 VC
With 275900-053# Alternator
82 PIM
MAP Sensor RLO 30
47 EPIM
Rail Pressure Sensor 53 PCR1 W 105 MIL

(Main) IG2
GIND 106 Glow Indicator
50 VCS2
Rail Pressure Sensor
(Sub) 85 PCR2
+B 68 E2S2 With 275900-053#
LOUT 116 LED
54 VG
r
MAF Meter
89 THA
e o
l s
t
t n
o
r e 55 E2G IREL 127
h S +B
r EDU Relay
o T n
s l i
o 80 VLU1
n e t GREL 27
e s i
s
S e
i o Glow Plug Relay
t
f 81 EGLS
i D P
L
R Intake Air Temperature Sensor
G
E (Intake Manifold) 86 THIA
Coolant Temperature Sensor 88 THW
With 275900-053# MREL 126

Main Relay
Battery Fluid Temperature Sensor 84 THB OILM 91

Meter ECU
Fuel Temperature Sensor 87 THF
45 E2
Q004468E
Operation Section
1 – 23
+B
Clutch Switch 46 CLSW
TACH 104
Meter
56 NE+
Crankshaft Position 39 G+
Sensor
#4 38
57 NE-
Camshaft Position #3 37
Sensor 40 G-
#2 36
111 IGSW EDU
IG2 IGSW #1 35
121 ST1- PRD 33

120 STP
BATT
+B
Brake Switch SCV 14
Swirl Control Valve
(29 at 20 )
ECBV 16
EGR Cooler Bypass VSV
108 HSW (29.7 at 20 )
Heat Amplifier EGR 10
E-VRV(12 at 20 
125 AC1 EGRC 58

A/C Amplifier
EGR Cut VSV (36 at 20 )
117 THWO
A/C ECU or Meter
ACT 114
EDU A/C Amplifier
34 INJ1
Vehicle Speed Sensor CANH 94

103 SPD
CANL 95 J/C
EC 145
Body Earth
110 TC EOM 118
Test Connector
Q004469E
Operation Section
1 – 24
90 91 92 93 94 95 96 97 138 139 140

19 20 21 98 99 100101102103 104105
1 2 3 4 5 6 2 2 23 2 4 25 2 6 27 2 8 29 30 3 1 32 33 34 3 5 36 37 38 106107108109 110111 112113 141 142 143
7 8 9 10 11 12 3 9 40 4 1 42 4 3 44 4 5 46 47 4 8 49 50 51 5 2 53 54 55 114115116117 118119 120121 144 145 146

5 6 57 5 8 59 6 0 61 6 2 63 64 6 5 66 67 68 6 9 70 71 72 122123124125126127 128129
13 14 15 16 17 18 7 3 74 7 5 76 7 7 78 7 9 80 81 8 2 83 84 85 8 6 87 88 89 130131132133134135 136137 147 148 149
Q002653
Operation Section
1 – 25
7.3 IMV
Main Relay PCV (Suction Control Valve) (2.1 )

15A 111 +B PCV+ 6
Fuse-EFI 121 MREL PCV- 7
12V (111 ) 74 BATT PRD 30 EDU

35 E1
1 E01
DM 109
2 E02 Multi Display
Engine Earth LUSL 38
128 WFSE Diesel Throttle Drive IC
OBDII Check With MA275900-059#
Without MA275900-060#, -061#
Connector 129 SIL RB275900-067#, -068#
HA275900-071#
With MA275900-058#, -059#
RB275900 -066# VNTO 15
91 CAN+ VNT
ECT 92 CAN- Drive
VNTI 8
135 VCPA
134 VCP2
Without MA275900-059#
+B 27 VC
CANH 89
69 PIM
n MAP Sensor VSC
o
i 40 VCS CANL 90
t
i MAF
s Rail Pressure Sensor
o
) Meter 19 PCR1
P n
i (Main)
r a VPA
o
t
125
M
(
a
r
e r
l o Rail Pressure Sensor 29 PCR2 With MA275900-055#, -056#, -057#, -058#, -059#
e s n
o (Sub) RB275900-065#, -066#
c n i
t
c e i
S s
A 124 VPA2
o PI 73 Cruise Indicator
)
P IG2
r b
u
r
o Intake Air Temperature Sensor 25 THIA
o
t S e s
l
t
a
r
(
e r t
o e
r n Coolant Temperature Sensor 26 THW
l o S
h
e s T n
c n l i 57 VG
c e r e o MIL
A
S t
i W 117
o s s 68 VLU IG2
s i
e o
n
e D
P GIND 115 Glow Indicator
S 64 EGLS
t
f
i (111 )
L Fuel Temperature Sensor 33 THF IREL 119
R
+B
G Air Temperature Sensor 31 THA EDU Relay
E
EGR 52
With MA275900-055#, -056#, -057#, -058# +B
MA275900-059#,RB275900-065#, -066# E-VRV (12 at 20 
126 CCS
Cruise Control Switch
41 E2S (194 )
34 E2 GREL 114
65 EVG Glow Plug Relay
132 EPA2
133 EPA
Q004471E
Operation Section
1 – 26
18 NE+ +B
Crankshaft Position 58 G-
Sensor ECBV 42
28 NE- EGR Cooler Bypass VSV
Camshaft Position
66 G+ (29.7 at 20 )
Sensor EGRC 43
IGSW 120 IGSW
IG2 EGR Cut VSV (36 at 20 )
Brake Switch
78 ST1- TACH 108
METER
77 STP #4 24
BATT EDU
#3 23
EDU
With MA275900-058#, -059# #2 22
RB275900-066# EDU
#1 21
82 D EDU +B
IG1
D Switch
SCV 10
Without MA275900-058#, -059#
Swirl Control Valve
RB275900-066# (29 at 20 )
82 CLSW With MA275900-055#, -056#, -057#, -058#, -059#
IG1
Clutch Switch RB275900-065#, -066#
HA275900-070#
With MA275900-058#, -059# SCV2 11
RB275900-066#
Swirl Control Valve 2
106 NSW (29 at 20 )
Neutral Start Switch

EDU
INJF 20
76 HSW
A/C Amplifier
95 AC1
A/C Amplifier
Vehicle Speed Sensor
110 THWO SPD 96
A/C Amplifier
94 ACT
A/C Amplifier
101 OILM
Oil Monitor
TC 118 Check Connector
102 IMI
Immobilizer
EOM 113
103 IMO
Immobilizer
EC 70
79 VCH
Viscous Amplifier
72 VCT Body Earth
Viscous Amplifier
17 ALT
Alternator
Q004472E
Operation Section
1 – 27
1 2 3 4 5 6 7 35 36 37 38 39 40 41 70 71 72 73 74 75 105 106 107 108 109 110 111
8 9 10 11 12 13 14 15 16 17 4243 44 45 46 47 48 49 50 51 52 53 76 77 78 79 80 81 82 8384 85 112 113114 115116 117 118 119120121

18 19 20 21 22 232425 26 27 5455 5657 5859 6061 86 87 88 89 90 9192 93 94 95 96 122 123 124125126127128129
28 29 30 31 32 33 34 6263 64 65 66 67 6869 979899 100 101 102103104 130 131 132133 134135
Q004470E
Service Department DENSO CORPORATION

1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan

Toyota 1kd2kd Common Rail System

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5/21/2018 Toyota1KD/2KDCommon RailSystem-slidepdf.

TOYOTA 1KD/2KD ENGINE

Issued : September 2009

 Single microinjection operation

 Detecting the change in rotational speed via injection

1. PRODUCT APPLICATION INFORMATION

5. FUEL INJECTION CONTROL

6. DIAGNOSTIC TROUBLE CODES (DTC)

1. PRODUCT APPLICATION INFORMATION

1.2 Applicable Vehicles

Vehicle Name Engine Type Engine Displacement Remarks

1.3 Applicable Product List

295050-007# 23670-30380 Different connector, for use with cylinders 1

MA275900-055# 89661-0KN00 1KD, MT, PT-4WD, Europe, Euro 4

1.4 System Outline

2.1 Change Item

to Fuel Tank to Fuel Tank

2.2 Suction Control Valve (SCV)

Needle Valve Armature

Valve Body Solenoid

Operational Concept Diagram

Short Duty ON Long Duty ON

Cylinder Small Opening Cylinder Large Opening

(1) SCV types (SV1, SV2)

larger than the SV2.

SV1 Type SCV SV2 Type SCV

3.1 Change Item

Rail Pressure Sensor Pressure Discharge Valve

4.1 Change Items

295050-007# SM295050-018# 295050-008#

http://slidepdf.com/reader/full/toyota-1kd2kd-common-rail-system Q004462E 12/31

4.2 Quick Response (QR) Codes

QR Codes ( 9.9 mm) QR Codes ( 9.9 mm)

ID Codes (30 Base-16 Characters) ID Codes (30 Base-16 Characters)

295050-007# SM295050-018# 295050-008#

180 MPa 140 MPa

Actuating Pulse Width TQ

5. FUEL INJECTION CONTROL

5.1 Change Item

5.2 Injection Pattern

Pilot Injection 1 Pilot Injection 2

Note) TOYOTA terminology is used in this Q004465E

5.3 Microinjection Quantity Learning Control

(3) Control outline

Determination for learning conditions

shows the specific details for learning determinations.

Engine Rotational Speed

Single microinjection operation

Detecting the change in rotational speed via injection

Engine Rotational Speed

Q Map Value Actual Injection

Injection Pulse Width TQ

No Load 3000 - 4000 rpm Non-Injection Learning

Rail Pressure Adjusting

5.4 Wide-Range Cylinder Correction Control

(2) Control outline

Difference Between Both Values Learned

Command Actual Injection Actual Rotational

Wide-Range Injection Rotational

Includes Error from Compatible Vehicle