Turbocharged diesel engines are produced and installed by the Toyota concern on its cars since the last century. The first power unit equipped with a Common Rail fuel injection system was manufactured in 1999. This engine had the index 1CD-FTV. Cars equipped with such a unit were labeled as D-4D. Denso company was responsible for the development of the fuel system.
The first modifications of the 1CD-FTV engine were installed on Toyota vehicles until 2006. Later, the power unit was modernized and received the index 1AD-FTV. The 2-liter motor was produced for several years, was characterized by reliability and unpretentiousness.
Despite the excellent technical characteristics of the 2-liter D-4D motor, the turbodiesel has characteristic shortcomings and defects. The main trouble to the owners of the car brings the fuel system. Denso equipment in general has good technical parameters and works perfectly in tandem with the turbodiesel. But if the fuel system fails, it is difficult and expensive to repair due to the peculiarities of the design. The manufacturer has not supplied spare parts for injectors and fuel injectors for a long time. The purchase of ready-made kits cost a large sum.
Design features of the powertrain and fuel system of the Toyota 2.0 D-4D
Depending on the modification, the power unit 1CD-FTV develops power from 90 to 116 horsepower. The motor is equipped with 16 valves on 4 cylinders, the cylinder head is made of aluminum alloy. The engine includes camshafts in the number of 2 units without hydrocompensators. The body is made of cast iron, in which the cylinders are bored, there are no liners in the motor.
It is possible to adjust the thermal clearances of the valves. To do this, it is necessary to replace special washers. This does not require disassembly of the camshaft. The adjustment procedure is simpler than on other turbodiesels.
The 1CD-FTV motor includes an intake manifold. To reduce the turbulence of the air flow, the system is equipped with a receiver and channels of equal length. This design allowed to achieve an even distribution of the incoming flow to the cylinders. A hydraulic tensioner is used to adjust the timing belt. The belt is used to control the operation of the fuel and oil pump, pump.
Belt drive valve block is responsible for the rotation of the camshaft of the exhaust valves. The intake camshaft rotates from the exhaust camshaft. Torque transmission is accomplished by a gear train. To reduce the coefficient of friction piston skirts are treated with special polymer compositions.
The engine 1CD-FTV does not start – what is the reason?
Most often, problems with starting the Toyota D-4D turbodiesel are caused by the fuel system, namely injectors and the fuel injector. But there are other reasons in which the power unit refuses to start. First of all, the problems can be associated with wear and tear of the starter. Service centers do not immediately pay attention to this node. A long repair is associated with checking the injectors and the fuel injector, after which the turn comes to the starter.
Even less often the problems of starting the engine are associated with faulty wiring. With prolonged use of the car wires are gradually frayed. Most often the cables to the pressure sensor of the intake valve suffer. Such a defect is indicated by an error, the indication is present even when the engine is not started. In some cases, the wires to the engine control unit are frayed. The readings from the sensors in this case are not visible on the diagnostics.
Problems in the operation of the motor – possible causes
One of the main problems that the owner of a Toyota with a 1CD-FTV engine can face is the lack of traction, loss of power, increased smoke, vibrations. In some cases, the motor stalls at the warm-up stage. First of all, an experienced master pays attention to the condition of the EGR valve, which is turned on when the coolant reaches a temperature of 60-80 degrees.
A possible solution to the problem is to clean the EGR valve, as well as the entire exhaust gas recirculation system. If the problem recurs, the EGR valve is simply plugged. The engine performance remains unchanged.
Turbine malfunctions and failures
As a turbocharger on two-liter 1CD-FTV engines, a Garrett unit with the index GTA17V is used. Such turbines are installed in pair with engines with an output of 110 horsepower. Model GTA17V has variable geometry, is characterized by reliability and wear resistance. Failure of the turbine is associated with high mileage, as well as the use of poor-quality lubricant. The main symptoms of failure are increased oil consumption, extraneous noise and grinding, poor response to the gas pedal.
GTA17V turbines are characterized by a special geometry, which is controlled by a vacuum actuator. If the geometry jams, turbine overblowing is detected. During diagnostics, the corresponding error codes are recorded. A possible option to eliminate the problem is to dismantle, disassemble and clean the turbine, namely the jammed blades. It is obligatory to defect and repair the shafts.
To adjust the geometry, a thrust screw with a lock nut is used. If work is carried out by an unqualified repairer, incorrect adjustment is possible. The maximum boost pressure cannot be achieved. In some cases, the electro-vacuum geometry control valve fails. Other negative consequences are cracks and other defects in the servo hose.
Troubleshooting fuel injectors of Toyota 2.0 D-4D engines
The fuel system of the Denso brand is the main source of problems of the power unit 1CD-FTV. The first generation of this type of engine was equipped with a dual-chamber fuel injector. The injection was provided by Denso HP2 radial plungers. The next generation of diesel turbo engines was equipped with a fuel injector with the index Denso HP3. The unit included one plunger pair. The booster pump on both of them was of the built-in type.
The advantage of the later version of the fuel injector was the presence of two bypass valves of solenoid type. These elements were responsible for fuel supply to the system and timely filling of the fuel injector. At the suction stage, the solenoid valves opened the fuel supply channel, while at the discharge stage they blocked it.
Any breakage of the bypass valve leads to a lack of fuel mixture supply. As a result, the motor simply does not start. In some situations, loss of contact in the valve block is recorded. In such cases, the power unit also does not start.
Reliability of the Denso fuel injector does not cause complaints. With timely maintenance and the use of high-quality fuel, the resource of the plunger pair reaches 300-400 thousand kilometers. Otherwise, there is a reduction in the period of operation of the fuel injector. The consequence of the breakdown is the inability to start the engine in hot mode, after a short stop.
Faults of injectors and oil seals on 1CD-FTV engines
The valve cover and injectors are separated by special gaskets, which are sealing rings. Wear of the gaskets leads to gradual leakage of oil. As a result, the surface of the valve cover becomes foggy. In addition to the above defect, which is not difficult to eliminate, problems with starting the engine can be caused by breakdowns of injectors
Defects of the engine Toyota 2.0 D-4D, associated with the work of injectors
One of the problems with 1CD-FTV motors is a problem with injector oil seals. Thin sealing rings are installed between the injectors and the valve cover. With prolonged use, these elements wear out. Oil starts to leak and accumulate on the surface of the valve cover. Replacement of oil seals solves the problem.
Power units Toyota 2.0 D-4D are equipped with Denso injectors, mounted on copper washers. It is obligatory to use rubber and plastic seals. If there is a need to replace the injectors, the seals are changed in a complete set.
In the process of intensive operation, the burnout of copper washers is often recorded. For a diesel engine, this means that exhaust gases from the combustion chamber enter the well. As a result, the injector heats up and jamming occurs. The higher the motor temperature, the faster the motor stalls.
Service life of 1CD-FTV engine injectors reaches 200 thousand kilometers and more. Such indicators are achievable with proper operation and use of quality fuel. Otherwise, it is the injectors that become the weak point of the fuel system. Their wear is the cause of fuel mixture backflow. For the power unit, such a defect turns out to be a loss of power, the appearance of extraneous noises, a decrease in traction characteristics.
Malfunctions of the fuel system are also manifested in error codes. Heavy wear of injectors does not provide the necessary fuel pressure. The engine starts to stall as it warms up or does not start. First of all, the condition of injectors on cylinders 1 and 4 is checked.
In case of difficulties with starting the 1CD-FTV motor, you can disconnect the temperature sensor. The indicator is located on the TNVD and it is not difficult to get to it. If after that you manage to start the motor, it is necessary to contact the service center. In most cases, the problem is in the reverse fuel drain in one or more injectors.
Until 2012, Denso injectors for Toyota engines were almost impossible to repair. The manufacturer did not supply spare parts to the market, forcing you to change the whole set. Accordingly, the cost of repair was very high. Over time, Denso injectors became several times cheaper, repair kits appeared on the market. But in this respect, similar elements of Bosch still win.
If you need to repair Denso injectors with four contacts, manufactured in the period from 1999 to 2003, then their prescription is not required. On such devices there is a built-in resistor responsible for the correction of fuel injection.
The injectors installed on cars after 2003 have 2 contacts each. On the elements themselves there are QR codes with corrective corrections. When repairing, it is necessary to generate and prescribe these data. Otherwise, the repair of injectors of different years of production is identical.