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MANUAL ENGINE 1/2KD-FTV TOYOTA SISTEMA COMNON RAIL • 1. ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-137 Supply Pump 1) General This supply pump (HP3 type) has been made shorter than the HP2 type that is used on other models. This has been accomplished through the adoption of an opposing plunger configuration (and by reducing the number of plungers from 4 to 2), resulting in a compact and lightweight supply pump. 4Specifications3 Model New Hilux Other Model Type HP3 (Outer Cam) HP2 (Inner Cam) A Length mm (in.) 190.2 (7.49) 252.0 (9.92) B Length mm (in.) 129.0 (5.08) 182.1 (7.17) Suction Control Valve 1 2 Plunger φ8.5×2 φ7.0×4 Weight g (lb.) 3,800 (8.38) 6,040 (13.32) 224EG21 HP2 A B The engine ECU learns and memorizes the pump discharge volume variances associated with the individual differences in the supply pumps. Therefore, make sure to perform the operation described below after replacing the supply pump. For details, see the Hilux Repair Manual.

• Connect an intelligent tester II to the DLC3 connector and use the tester to reset the learned value. Alternatively, connect the SST (0) between the TC and CG terminals of the DLC3 connector, and leave the ignition switch ON for approximately 3 minutes to reset the learned value. • After resetting, start the engine, allow it to idle* for approximately 1 minute, and turn the ignition switch OFF to enable the engine to memorize the learned value. *: The engine coolant temperature should be 60°C (140°F) or more, and the fuel temperature should be 20°C (68°F) or more. Service Tip 271EG155 HP3 A B • ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-138 2) Construction • The supply pump consists of an eccentric camshaft, ring cam, two plungers, four check valves, SCV (Suction Control Valve), fuel temperature sensor, and a feed pump. Maxwell Sv Software Informer there. • The two plungers are placed opposite each other outside of the ring cam.

Plunger Plunger Ring Cam Feed Pump Eccentric Camshaft 271EG157 271EG158 Eccentric Cam Portion Eccentric Cam Portion Ring Cam Check Valve (for Suction) Check Valve (for Discharge) Check Valve (for Suction) SCV Feed Pump to Common-rail Fuel Temp. Sensor Eccentric Camshaft Ring Cam 271EG156 Plunger Check Valve (for Suction) Plunger Check Valve (for Suction) from Fuel Tank (for Suction) to Fuel Tank (for Return) Check Valve (for Discharge) • ENGINE – 1KD-FTV AND 2KD-FTV ENGINES EG-139 3) Operation • Due to the rotation of the eccentric cam, the ring cam pushes plunger “A” upward as illustrated below. The force of the spring pulls plunger “B” (which is located opposite plunger “A”) upward.

As a result, plunger B draws fuel in, and plunger “A” pumps fuel at the same time. • The SCV controls the volume of fuel that is drawn into the plungers in accordance with the signals from the engine ECU.

Engine ECU Engine ECU Engine ECU Engine ECU B Ring Cam Eccentric Cam Check Valve (for Discharge) Check Valve (for Suction) A SCV 245EG08 • ENGINE – 1KD-FTV AND 2KD-FTV ENGINESEG-140 Common-Rail • The function of the common-rail is to store the fuel that has been pressurized by the supply pump. The common-rail is provided with a fuel pressure sensor, which detects the fuel pressure in the common-rail, and a pressure limiter that mechanically relieves the pressure in case the internal pressure of the common-rail rises abnormally.