1. Contents Click a Section Tab New M0del PRIUS 2009
Instructor & Technical Staff

2. Intake and Exhaust System Fuel System Emission Control System
New M0del PRIUS 2009
Engine Overall
Engine Proper
Valve Mechanism
Lubrication System
Cooling System
Intake and Exhaust System
Fuel System
Emission Control System
Ignition System
Engine Control System
Instructor & Technical Staff

3. Engine Overall
2ZR-FXE
2ZR-FXE engine is newly developed in-line, 4-cylinder, 1.8-liter, 16-valve, DOHC engine with VVT-i, ETCS-i, DIS and cooled EGR (Exhaust Gas Recirculation) control system

4. Engine Overall Specification Model New Previous Engine 2ZR-FXE 1NZ-FXE
New M0del PRIUS 2009
Engine Overall
Specification
Model
New
Previous
Engine
2ZR-FXE
1NZ-FXE
No. of Cylinders and Arrangement
4-cylinder, In-line 
Valve Mechanism
16-valve, DOHC,
Chain Drive, with VVT-i
Displacement [cm3 (cu. in.)]
1798 (110.0)
1497 (91.3)
Bore x Stroke [mm (in.)]
80.5 x 88.3 (3.17 x 3.48)
75.0 x 84.7 (2.95 x 3.33)
Compression Ratio
13.0
Max. Output [kW rpm]
Max. Torque [N·m rpm]
Firing Order
1 – 3 – 4 – 2
Oil Grade
API SL, SM or ILSAC
API SJ, SL or ILSAC
Oil Capacity [Liters
(US qts, Imp. qts)]
Dry
4.7 (5.0, 4.1)
4.1 (4.3, 3.6)
W/ Oil Filter
4.2 (4.4, 3.7)
3.7 (3.9, 3.3)
W/o Oil Filter
3.9 (4.1, 3.4)
3.4 (3.6, 3.0)
Instructor & Technical Staff

5. Engine Overall Specification Model New Previous Engine 2ZR-FXE 1NZ-FXE
Valve
Timing
Intake
Open
29° to -12° BTDC
18° to -15° BTDC
Close
61° to 102° ABDC
72° to 105° ABDC
Exhaust
31° BBDC
34° BBDC
3° ATDC
2° ATDC
Emission Regulation
Indonesia
EURO V
EURO IV
Engine Service Mass* (Reference)
[kg (lb)]
90 (198)
86.1 (189.8)
*: The figure shown is the weight of the part without coolant and oil

6. Engine Overall Features Long-reach Type Iridium-tipped Spark Plug
EGR Cooler
Electric EGR Valve
Roller Rocker Arm
VVT-i System for Intake
Hydraulic Lash Adjuster
Offset Crankshaft
Electric Water Pump
V-ribbed belt is eliminated

7. Engine Overall Main Features System Item Engine Proper
New M0del PRIUS 2009
Engine Overall
Main Features
System
Item
Engine Proper
High-expansion Atkinson cycle is adopted
The aluminum cylinder block is used
The offset crankshaft is used
Spiny type liners are used
The taper squish shape is used combustion chamber
The skirt position of each has a resin coating
Low-tension piston rings are used
Valve Mechanism
The VVT-i (Variable Valve Timing-intelligent) system is used
Hydraulic valve lash adjusters are used
Roller rocker arms are used
The timing chain and chain tensioner are used
Lubrication System
The oil filter with a replaceable element is used
Cooling System
The electric water pump is used
Intake and Exhaust System
The plastic intake manifold is used
The link-less type throttle body is used
The DC motor type EGR valve is used
The water-cooled type EGR cooler is used
Stainless steel exhaust manifold is used
2 TWCs (Three-Way Catalytic converter) are used
2-way exhaust control system is used
Instructor & Technical Staff

8. Engine Overall Main Features System Item Fuel System
New M0del PRIUS 2009
Engine Overall
Main Features
System
Item
Fuel System
The fuel returnless system is used
12-hole type fuel injectors are used
Quick connectors are used
Ignition System
DIS (Direct Ignition System) is used
Long-reach type iridium-tipped spark plugs are used
Serpentine Belt Drive System
The V-ribbed belt is discontinued
Emission Control System
EGR (Exhaust Gas Recirculation) control is used
The evaporative emission control system is used
Engine Control System
MRE (Magnetic Resistance Element) type VVT sensors are used
The ETCS-i (Electric Throttle Control System-intelligent) is used
The flat type knock control sensor is used
Instructor & Technical Staff

9. 2ZR-FXE Engine Serial Number
Engine Overall
Identification Information
Engine serial number is stamped on the cylinder block of the engine as shown in the figure
2ZR-FXE Engine Serial Number

10. Engine Proper Cylinder Head
Cylinder head structure is simplified by separating camshaft housing from cylinder head
Cylinder head which is made of aluminum, contains a pentroof combustion chamber
Bearing Cap
29°
Camshafts
Camshaft Housing
Cylinder Head
Cylinder Block
Taper Squish

11. Engine Proper
Piston
The pistons are made of aluminum alloy to allow them to be compact and lightweight
PVD Coating
Taper Squish Shape
Resin Coating
(Piston Skirt)

12. Valve Mechanism General
Valve mechanism consists of the roller rocker arms, hydraulic lash adjusters and VVT-i system
Exhaust Camshaft
Intake Camshaft
Camshaft Timing Gear
Camshaft Timing Sprocket
Roller Rocker Arms
Chain Tensioner
- Ratchet type Non-return Mechanism
Piston
Hydraulic Lash Adjusters
Timing Chain (8 mm pitch)
Valve
Timing Chain (7 mm pitch)

13. Valve Mechanism Hydraulic Lash Adjuster
New M0del PRIUS 2009
Valve Mechanism
Hydraulic Lash Adjuster
Maintaining a constant zero valve clearance through use of oil pressure and spring force
Plunger
Low Pressure Chamber
Zero Valve Clearance
Oil Passage
Check Ball
Check Ball Spring
The hydraulic lash adjuster, which is located at the fulcrum of the roller rocker arm, consists of plunger, plunger spring, check ball and check ball spring.
Oil in chamber is stored and it decreases the clearance.
High Pressure Chamber
Plunger Spring
Oil Passage
Instructor & Technical Staff

14. Service Point (Valve Mechanism)
New M0del PRIUS 2009
Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
1. Pushing check ball down by using SST
SST
SST:
Charge the clean engine oil to hydraulic lash adjuster, when the hydraulic lash adjuster relation parts are disassembled.
[Caution at Installation for Hydraulic lash Adjuster]
- Keep the hydraulic lash adjuster free from dirt and foreign objects.
- Only use clean engine oil when engine oil is charged.
- DO NOT disassemble.
Hydraulic Lash Adjuster
Correct
Incorrect
Instructor & Technical Staff

15. Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
2. Immerse hydraulic lash adjuster in clean engine oil, then compress and return the plunger with SST 5 to 6 times
Clean Engine Oil

16. Service Point (Valve Mechanism)
New M0del PRIUS 2009
Service Point (Valve Mechanism)
Hydraulic Lash Adjuster
Engine oil changing procedure
3. Press the plunger by finger and check the blockage of plunger
If plunger is compressed after 3 times trial, replace to new one
Instructor & Technical Staff

17. Lubrication System General
New M0del PRIUS 2009
Lubrication System
General
Oil filter with a replaceable element is used
Oil Filter Cap
Element
Destination
Maintenance Interval
U.S.A.
Replace at every 5000 miles or 6 months
Canada
Replace at every 8000 km or 6 months
Europe
Normal Condition
Replace at every km / 9000 miles or 12 months
Severe Condition
Replace at every 7500 km / 4500 miles or 6 months
Australia, Mexico,
Taiwan
Replace at every km / 6000 miles or 12 months
Replace at every 5000 km / 3000 miles or 6 months
[Maintenance Interval]
The maintenance interval of engine oil and oil filter is as follows.
U.S.A.
Replace at every 5000 miles or 6 months
Canada
Replace at every 8000 km or 6 months
Europe
[Normal] Replace at every km / 9000 miles or 12 months
[Severe] Replace at every 7500 km / 4500 miles or 6 months
Australia / Taiwan / Mexico
[Normal] Replace at every km / 6000 miles or 12 months
[Severe] Replace at every 5000 km / 3000 miles or 6 months
Instructor & Technical Staff

18. Cooling System General
New M0del PRIUS 2009
Cooling System
General
The drive belt and pulley are discontinued by providing the electric water pump
Water Temperature Sensor
Reservoir Tank
EGR Valve
Air Release Valve
From Heater Core
To Heater Core
From Exhaust Pipe Gas Control Actuator (Not for Indonesia)
Water Pump
Throttle Body
The electric water pump for heater which the pervious PRIUS is using is discontinued.
To Exhaust Pipe Gas Control Actuator (Not for Indonesia)
EGR Cooler
From Radiator
To Radiator
Instructor & Technical Staff

19. Cooling System System Diagram Cylinder Head Heater Core Throttle Body
New M0del PRIUS 2009
Cooling System
System Diagram
Cylinder Head
Heater Core
Throttle Body
Cylinder Block
Exhaust Heat Recirculation System (Not for Indonesia)
Water Pump
EGR Cooler
Water Inlet with Thermostat
: Engine Coolant Flow
Thermostat Valve Opening Temperature: 80 to 84 °C (176 to 183 °F)
Radiator
Reservoir Tank
Instructor & Technical Staff

20. Cooling System Electric Water Pump
New M0del PRIUS 2009
Cooling System
Electric Water Pump
The electric water pump is newly adopted to enhance warm-up performance and reduce cooling losses
Electric Water Pump
Stator
Rotor
The ECM regulates the amount of circulating engine coolant in accordance with engine operation conditions.
As a result, the engine will be warmed up more quickly, and cooling loss will be reduced.
Shaft
Motor
Instructor & Technical Staff

21. Service Point (Cooling System)
Engine Coolant Replacement
Refilling method
Reservoir Tank Cap
Cylinder Block Drain Cock Plug
Air Release Valve
Loosen the radiator drain cock plug and drain the coolant
Loosen the cylinder block drain cock plug
Tighten the drain cock plugs
Remove the reservoir tank cap
Add the SLLC of the following value
Connect the hose to the air release valve
Loosen the air release valve
Tighten the air release valve
Item
Capacity
Engine Coolant
w/o Exhaust Heat Recirculation System
6.5 liters
(6.9 US qts, 5.7 Imp. qts)
Radiator Drain Cock Plug
Air Release Valve

22. Service Point (Cooling System)
Engine Coolant Replacement
Refilling method
B Line
Remove the reservoir tank cap, and add the SLLC to B line of reservoir tank
Put the engine in inspection mode
Install the reservoir tank cap
Warm up the engine until the thermostat opens
After engine has warmed up, run the engine using the following cycle for at 7 minutes:
At 3000 rpm for 5 seconds, at idle speed for 45 seconds
After engine has cooled down, check that the coolant level is between FULL and LOW
FULL
LOW

23. Intake and Exhaust System
Intake Manifold
Intake manifold is made of plastic for weight reduction
EGR chamber is built into the intake manifold to uniformly distribute EGR gas into cylinders
Intake Manifold
Throttle Body
EGR Gas
Vacuum Sensor
Blowby Gas
Purge VSV
Fuel Vapors

24. Intake and Exhaust System
Main Muffler
2-way exhaust control system is used to enable a quieter operation at lower engine speed, and reduce back pressure at higher engine speed
Main Muffler
Low Engine Speed (Valve is closed)
Middle to High Engine Speed (Valve is opened)
Control Valve

25. Fuel System
General
The fuel returnless system is used to reduce evaporative emission
Multiplex layered plastic fuel tank
Fuel Delivery Pipe
12-hole Type Fuel Injector
Fuel Pump Assembly
Fuel Filter
Pressure Regulator
Fuel Sender Gauge
Charcoal Canister
Quick Connector

26. Emission Control System
General
The EGR control is used to realize high fuel efficiency
Charcoal Canister Assembly
Purge Valve
EGR Valve
PCV Valve *2
EGR Cooler

27. Emission Control System
New M0del PRIUS 2009
Emission Control System
EGR Valve and EGR Cooler
Step motor type EGR control valve is used to precisely control the EGR gas flow amount
EGR cooler cools the EGR gas to improve the EGR efficiency
[EGR Control Valve]
Coil A
Valve
To Intake Manifold A
EGR cooler reduces the combustion temperature and increases the EGR gas volume by cooling the EGR gas.
As a result, some losses are reduced.
[EGR Cooler]
Engine Coolant
From EGR Cooler
EGR Gas
A - A Cross Section
Instructor & Technical Staff

28. Emission Control System
Vacuum Sensor
Vacuum sensor that consists of the silicon chip is used to measure the intake manifold pressure for EGR control
Vacuum Sensor
[Vacuum Sensor Output]
4.2
Output Voltage (V)
2.4
Silicon Chip
0.6
Atmosphere Pressure
Vacuum
Intake Manifold Pressure

29. Emission Control System
New M0del PRIUS 2009
Emission Control System
EGR Control System
This system recirculates some of the EGR gas to the combustion chambers for fuel economy
Throttle Position Sensor Signal
Vacuum Sensor
ECM
Throttle Valve Control
Crankshaft Position Sensor
Engine Coolant Temperature: 70 °C (158 °F) or more
Engine load is a specified value
Mass Air Flow Meter
Intake Air Temperature Sensor
Open
Engine Coolant Temperature Sensor
EGR Valve
This system reduced the following losses and fuel consumption by recirculating some of the EGR gas to the combustion chambers.
Pumping loss
Recirculation of EGR gas allows the pressure in the intake manifold to be made closer to atmospheric pressure.
Cooling loss
Mixing intake air and EGR gas allows oxygen concentration in the combustion chamber to be reduced, moderating combustion and thereby reducing combustion temperature.
Exhaust loss
As the combustion temperature is lowered, it becomes harder for the mixture to pre-ignite. This allows more ignition timing advance to be used. As a result of using more ignition timing advance, the pressure in the cylinder at bottom dead center after expansion of the burning mixture will decrease.
Power Management Control ECU
Accelerator Pedal Position Sensor
Engine
EGR Cooler
Power Management Bus
EGR Gas
Instructor & Technical Staff

30. Service Point (Emission Control System)
Service Information
[Data List]
Tester Display
Measurement Item/Range
Target EGR Position
Target EGR position: Min.: 0%, Max.: 100%
EGR Step Position
EGR step position: Min.: 0 step, Max.: 120 step
EGR/VVT Monitor
EGR monitor: Not Avl or Avail
EGR monitor: Compl or Incmpl
EGR/VVT Monitor ENA
EGR monitor: Unable or Enable
EGR/VVT Monitor CMPL
[Active Test]
Tester Display
Control the EGR Step Position
Test Part
Open or closed EGR valve
Control Range
From 0 to 110 steps
Diagnostic Note
EGR valve fully closed at step position 0, and fully open at step position 110
Amount of EGR gas, flowing into intake manifold, varies in accordance with EGR valve opening angle

31. 2ZR-FXE Engine (DENSO: SC20HR)
Ignition System
Spark Plug
Long-reach, thin type iridium-tipped spark plugs are used
2ZR-FXE Engine (DENSO: SC20HR)
Conventional Spark Plug
Hex.14
Hex.16
M12
M14
Iridium
Plug Gap 1.1 mm (0.04 in.)

32. Service Point (Ignition System)
New M0del PRIUS 2009
Service Point (Ignition System)
Spark Plug
Recommend tools
Spark Plug Wrench 14 mm ( C220)
[Spark Plug Removal]
Compression Gauge
Compression Gauge Adapter
[Compression Inspection]
Instructor & Technical Staff

33. Engine Control System Main Components of Engine Control System
System Control Table
Component
Outline
Mass Air Flow Meter
Hot-wire Type
Crankshaft Position Sensor [Rotor Teeth]
Pick-up Coil Type [36-2]
Camshaft Position Sensor [Rotor Teeth]
MRE (Magnetic Resistance Element) Type [3]
Throttle Position Sensor
Non-contact Type
Knock Sensor
Built-in Piezoelectric Element Type
Heated Oxygen Sensor
Cup Type with Heater
Air Fuel Ratio Sensor
Planar Type with Heater
Engine Coolant Temperature Sensor
Thermistor Type
Fuel Injector
12-hole Type
ECM location
Engine Compartment

34. Engine Control System Main Components of Engine Control System
Parts Location
Ignition Coil
Camshaft Oil Control Valve
Fuel Injector
Camshaft Position Sensor
EGR Valve
Knock Sensor
Water Pump
Throttle Body
Engine Coolant Temperature Sensor
Vacuum Sensor
Purge Valve
Crankshaft Position Sensor

35. Camshaft Position Sensor
New M0del PRIUS 2009
Engine Control System
Camshaft Position Sensor
MRE (Magnetic Resistance Element) type camshaft position sensor is used for intake camshaft
Camshaft Position Sensor
Intake Camshaft
Timing Rotor
Instructor & Technical Staff

36. Engine Control System Camshaft Position Sensor
New M0del PRIUS 2009
Engine Control System
Camshaft Position Sensor
Signal output at extremely low speed rotation can be ensured
MRE Type
Pick-up Coil Type
No Detection
Engine Speed
Engine Speed
Sensor Output
Sensor Output
Analog Output
Digital Output
Time
Time
No Detection
Instructor & Technical Staff

37. Engine Control System Water Pump Control
New M0del PRIUS 2009
Engine Control System
Water Pump Control
The ECM controls the water pump by calculating the necessary amount of coolant flow based on engine coolant temp., engine speed and vehicle speed
Water Pump Relay
Engine Speed
Vehicle Speed
Engine Coolant Temp.
Battery
EFI Relay
Pump Motor Speed Pulse Signal
ECM
Electric Water Pump
Driver Circuit
Water Pump Motor
Pump Motor Speed
The pump motor speed is controlled steplessly using a duty cycle signal sent from the ECM.
Power Management Bus
Air Conditioning Amplifier
Instructor & Technical Staff