EG-156

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

J ENGINE PROPER 1. Cylinder Head Cover

D The cylinder head cover is made of plastic to reduce weight and noise. D A baffle plate is provided on the inside of the cylinder head cover to reduce the consumption of engine oil through blow-by gas. A A

Baffle Plate A A Cross Section

271EG99

2. Cylinder Head Gasket

D A steel-laminate type cylinder head gasket is used. D A shim has been provided around the cylinder bore to increase the sealing surface, thus achieving excellent sealing performance.

A Shim Front A Outer Cylinder Side Bore Side A A Cross Section

271EG100

Service Tip There are 5 sizes of new cylinder head gaskets, marked A, B, C, D, or E according to piston protrusion. For details, refer to the Hilux Repair Manual. A B C Rear D E
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ENGINE 1KD-FTV AND 2KD-FTV ENGINES

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3. Cylinder Head
D The cylinder head is made of aluminum alloy. The injector has been located in the center of the combustion chamber in order to improve engine performance and to achieve cleaner emission. D Two intake ports with different shapes have been combined to promote the mixture of fuel and air by optimizing the swirl in the cylinder. D A vertical 2-stage construction is used for the water jacket to improve cooling performance. D A glow plug is placed between the intake ports of each cylinder to ensure startability. D The passage for the EGR is provided in the cylinder head. By cooling the exhaust gas, it is possible to recirculate the great amount of exhaust gas. D On the models without EGR control, an EGR hole cover plate which plugs the EGR passage is provided. D The cylinder head bolt employs plastic region tightening bolts. Injector Hole

EG

EX

EX

EX

EX

IN

IN

IN

IN

EGR Passage

Glow Plug Hole

195EG42

Water Jacket
195EG41

4. Cylinder Block
D The cylinder block is constructed of liner-less cast iron alloy. D A rib has been provided to the cylinder block to reduce engine vibration.

Rib

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EG-158

ENGINE 1KD-FTV AND 2KD-FTV ENGINES

5. Balance Shaft
D For in-line 4-cylinder engines, the main cause of vibration is the imbalanced inertial force of reciprocating parts, such as the pistons and connecting rods. The 1KD-FTV engine vibration has been reduced by using 2 balance shafts to cancel the imbalanced inertial force, thereby reducing engine noise (booming noise). D These balance shafts are built into the cylinder block. Driven by the timing gear, the balance shafts rotate at twice the speed of the crankshaft and in the opposite direction of each other.

Balance Shaft No. 1 Supply Pump Drive Gear Oil Pump Drive Gear

Crankshaft Timing Gear Idle Gear Balance Shaft No. 2

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ENGINE 1KD-FTV AND 2KD-FTV ENGINES

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6. Piston
A piston provided with combustion chamber is used. The piston is made of aluminum alloy. A cooling channel has been provided to reduce the piston temperature, and achieve high reliability. An Ni-resist cast iron ring carrier is used for the top ring groove to improve the wear resistance. On the models with 1KD-FTV engine and 2KD-FTV engine non-compliant with emission regulations, a PVD (Physical Vapor Deposition) coating has been applied to the surface of the No. 1 compression ring, to improve its wear resistance. D On the models with 1KD-FTV engine and models for Thailand with 2KD-FTV High Version engine, the piston skirt portion has been coated with resin to reduce the friction loss. D D D D D Ni-resist Cast Iron Ring Carrier Ni-resist Cast Iron Ring Carrier Ni-resist Cast Iron Ring Carrier

EG

Cooling Channel
1KD-FTV Engine

Resin Coating
271EG103

Cooling Channel

Resin Coating*
00LEG04

Cooling Channel

041MO013

2KD-FTV Engine (Except Models Compliant with EURO IV Emission Regulations)

2KD-FTV Engine (Models Compliant with EURO IV Emission Regulations)

*: Models for Thailand with 2KD-FTV High Version engine

7. Connecting Rod and Connecting Rod Bearing

D The connecting rods are made of high-strength material to ensure the proper strength. D Knock pins are used at the mating surfaces of the bearing caps of the connecting rod to minimize the shifting of the bearing caps during assembly. D Plastic region tightening bolts are used. D An aluminum bearing is used for the connecting rod bearings.

Connecting Rod Bearing Knock Pin

Plastic Region Tightening Bolt

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ENGINE 1KD-FTV AND 2KD-FTV ENGINES

8. Crankshaft and Crankshaft Bearing

D The crankshaft has 5 journals and 8 balance weights. D All pin and journal fillets are roll-finished to maintain adequate strength. D The crankshaft bearing is made of aluminum alloy. D The lining surface of the crankshaft bearing has been micro-grooved to achieve an optimal amount of oil clearance. As a result, cold-engine cranking performance has been improved and engine vibrations have been reduced. D The upper main bearing has an oil groove around its inside circumference. Roll-finished Oil Hole Oil Grooved Upper Main Bearing

Micro-grooved

Lower Main Bearing

271EG105

9. Crankshaft Pulley
The rigidity of the torsional damper rubber is used to reduce noise. Torsional Damper Rubber

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