ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

271EG99

A A

Baffle Plate

A – A Cross Section

271EG100

Front

A

A

Shim

CylinderBore Side

A – A Cross Section

OuterSide

Service Tip

There are 5 sizes of newcylinder headgaskets,marked “A”, “B”, “C”, “D”, or “E” accordingto piston protrusion. For details, refer to theHilux Repair Manual.

271EG101

ABC

Rear

DE

EG-156

JENGINE PROPER

1. Cylinder Head Cover

D The cylinder head cover is made of plastic toreduce weight and noise.

D A baffle plate is provided on the inside of thecylinder head cover to reduce the consumptionof engine oil through blow-by gas.

2. Cylinder Head Gasket

D A steel-laminate type cylinder head gasket is used.

D Ashimhasbeenprovided around the cylinder bore to increase the sealing surface, thus achieving excellentsealing performance.

EG

ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

195EG41195EG42

Injector Hole

IN IN IN IN

EGR Passage Glow Plug HoleWater Jacket

EX EX EX EX

271EG102Rib

EG-157

3. Cylinder Head

D Thecylinder head ismade of aluminum alloy.The injector has been located in the center of the combustionchamber 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 byoptimizing 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 torecirculate 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.

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.

ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

195EG47

Balance Shaft No. 1

Oil PumpDrive Gear

CrankshaftTiming Gear

Idle GearBalance Shaft No. 2

Supply PumpDrive Gear

EG-158

5. Balance Shaft

D For in-line 4-cylinder engines, themain cause of vibration is the imbalanced inertial force of reciprocatingparts, such as the pistons and connecting rods. The 1KD-FTVengine vibration has been reduced by using2 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 rotateat twice the speed of the crankshaft and in the opposite direction of each other.

EG

ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

041MO013271EG103 00LEG04

Ni-resist CastIron Ring Carrier

Cooling ChannelResinCoating

1KD-FTV Engine

Ni-resist CastIron Ring Carrier

ResinCoating*

Cooling Channel

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

Ni-resist CastIron Ring Carrier

Cooling Channel2KD-FTV Engine

(Models Compliant withEURO IV Emission Regulations)

271EG104

Knock Pin

ConnectingRod Bearing

Plastic RegionTightening Bolt

EG-159

6. Piston

D A piston provided with combustion chamber is used.D The piston is made of aluminum alloy.D A cooling channel has been provided to reduce the piston temperature, and achieve high reliability.D An Ni-resist cast iron ring carrier is used for the top ring groove to improve the wear resistance.D On the models with 1KD-FTV engine and 2KD-FTV engine non-compliant with emission regulations,a PVD (Physical VaporDeposition) 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-FTVHigh Version engine, thepiston skirt portion has been coated with resin to reduce the friction loss.

*: 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 theshifting of the bearing caps during assembly.

D Plastic region tightening bolts are used.D An aluminum bearing is used for the connecting rod bearings.

ENGINE – 1KD-FTV AND 2KD-FTV ENGINES

271EG105

Roll-finished

Oil Hole Oil Grooved

Upper Main Bearing

Micro-grooved Lower Main Bearing

271EG106

Torsional DamperRubber

EG-160

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 oilclearance. As a result, cold-engine cranking performance has been improved and engine vibrations havebeen reduced.

D The upper main bearing has an oil groove around its inside circumference.

9. Crankshaft Pulley

The rigidity of the torsional damper rubber is usedto reduce noise.