4 Engine Overall Specifications Model Verso-s Urban Cruiser No. of Cylinders and Arrangement4-Cylinder, In-lineValve Mechanism8-Valve SOHC, Chain DriveCombustion ChamberDirect Injection TypeFuel SystemCommon-rail TypeDisplacement [cm3]1,364Bore x Stroke [mm]73.0 X 81.5Compression Ratio16.5 : 1Maximum Output (EEC) rpm]3,800Maximum Torque (EEC) rpm]1,800 to 2,800Valve TimingIntakeOpen4º BTDCClose36º ABDCExhaust44º BBDC4º ATDCFiring Order1 – 3 – 4 - 2Emission RegulationEURO VEuro IVEngine OilViscosity / Grade0W-30 or 5W-30 /ACEA C2
5 Engine Overall Main Features [1/2] Item Feature Achieved Performance Engine ProperA Cylinder Head, Cylinder Block, and Piston Made of Aluminum Alloy are Used(2), (3)The Thin Cast-iron Liner is Used in The Cylinder Block(1), (3)The Piston Skirt is Coated with Resin(1), (2)Valve MechanismA Timing Chain and Chain Tensioner is Used(3), (4)Intake SystemAn Air-cooled Type Intercooler is Used(1), (5)A DC Motor Type Diesel Throttle Control Motor is Used in The Throttle Body(1), (3), (5)The Variable Nozzle Vane Type Turbocharger Driven by a DC Motor is UsedExhaust SystemThe Exhaust Manifold Converter Uses Oxidation Catalyst(5)The DPF Catalytic Converter is UsedA Dual-wall Pipe Type Stainless Steel Exhaust Manifold is Used(1), (2),(3), (5)(1) High performance and fuel economy (2) Low noise and vibration(3) Lightweight and compact design (4) Good serviceability(5) Clean emission
6 Emission Control System Engine OverallMain Features [2/2]ItemFeatureAchieved PerformanceLubrication SystemAn Aluminum Alloy Made Water-cooled Type Oil Cooler is used(3)Element Replacement Type Oil Filter is Used(4)Oil Pump (Electrically Variable Oil Pressure Type) is Used(1), (2)Cooling SystemTOYOTA Genuine Super Long Life Coolant (SLLC) is UsedAfter Warm-up Circulation System is Used(1), (5)Fuel SystemA Common-rail Type Fuel Injection System is Used(1), (2), (5)Compensation Value and Data Matrix Code (DMC) Printed Piezo Type Injector is UsedEmission Control SystemA DC Motor Type EGR Valve is UsedA Water-cooled Type EGR Cooler with Bypass Switching Valve is UsedEngine Control SystemAn Air Flow Meter is Used(5)The Non-contact Sensor is Used in The Accelerator Pedal Position Sensor and Throttle Position Sensor(1)A Catalyst Support Control is UsedA Pilot Injection Control is UsedA Oil Maintenance Management System is UsedBrake Override System is Used
7 Engine OverallEngine Serial NumberEngine Serial Number
8 Intake System Overall A DC motor type throttle body is used A variable nozzle vane type turbocharger driven by a DC motor is usedTurbochargerDiesel Throttle
9 Intake System Parts Location DC Motor Type VN (Variable Nozzle) Vane TurbochargerDC Motor Type Diesel Throttle
10 Exhaust System Overall A stainless steel exhaust manifold and exhaust pipe are used for weight reduction and proper rust resistanceExhaust Manifold Converter Uses Oxidation CatalystExhaust Manifold ConverterDPF Catalytic ConverterMain MufflerFront Exhaust Pipe Assembly
11 Lubrication System Overall Lubrication circuit is fully pressurized and oil passes through oil filterAn electric variable oil pressure type oil pump, which can control the pressure of the engine oil in 2 stages in accordance with driving conditions, is usedOil GradeACEA C2Oil Viscosity (Preferred)0W-30 or 5W-30Drain and Refillw/ Oil Filter Change4.1 litersw/o Oil Filter Change3.6 litersDry Fill4.5 litersType of Engine Oil FilterReplaceable Element Type
12 Oil Filter Bracket (Aluminum) Lubrication SystemOil FilterElement Replacement Type Oil Filter is UsedOil Filter Bracket (Aluminum)Oil Filter CapOil Filter Element
13 Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) This oil pump can control the engine oil pressure in 2 stages to reduce energy loss and improve fuel efficiencyOil Pressure Switching ValveTo Engine PartsSleeve ValveEngine Speed [rpm]Oil Pressure [kPa]Opening Pressure of Piston Oil JetAn electric variable oil pressure type oil pump, which can control the pressure of the engine oil in 2 stages in accordance with driving conditions, is used. As a result, energy loss caused by oil pump operation has been reduced to achieve improved fuel efficiency. - Engine is quickly warmed up by stopping operation of the piston oil jet.The oil pressure switching valve is controlled by ECM.Relief ValveFrom Oil PanOil PumpRelief Valve Spring
15 Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) System DiagramEngine CoolantTemperature SensorTHWECMOil Pressure SwitchingValve AssemblyCrankshaft Position SensorNEV2OEngine Oil Level SensorOILHAccelerator Pedal AssemblyVPAVPA2ON / OFFOil Pressure SenderGauge AssemblyPOPTHW:Engine Coolant Temperature Sensor SignalNE:Crankshaft Position Sensor SignalOILH:Engine Oil Level Sensor SignalVPA:Accelerator Pedal Position Sensor SignalVPA2:Accelerator Pedal Position Sensor SignalPOP:Oil Pressure Sender Gauge SignalV2O:Oil Pressure Switching Valve Operation Signal
16 Opening Pressure of Piston Oil Jet Lubrication SystemOil Pump (Electrically Variable Oil Pressure Type)Oil Pressure Control (Low Pressure)When the ECM turns the oil pressure switching valve ON, sleeve valve and relief valve upward. As a result, opening pressure of relief valve decreasesTo Engine PartsONEngine Speed [rpm]Oil Pressure [kPa]Opening Pressure of Piston Oil JetOpenSleeve Valve "Rise"When the ECM turns the oil pressure switching valve ON, oil pressure is applied to the lower portion of the sleeve valve. This pushes the sleeve valve upward and moves the oil passage provided on the side of the sleeve valve upward also. At the same time, the relief valve is moved upward by the force of the relief valve spring. As a result, the opening pressure of the relief valve decreases and the engine oil pressure is controlled to a lower level.[Reference Oil Pressure]80 to 180 kPa (0.8 to 1.8 kgf/cm2, 12 to 26 psi)From Oil Pan
17 Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) Oil Pressure Control (High Pressure)When the ECM turns the oil pressure switching valve OFF, relief valve spring is compressed by sleeve valve. As a result, opening pressure of relief valve increasesTo Engine PartsOFFEngine Speed [rpm]Oil Pressure [kPa]Opening Pressure of Piston Oil JetCloseSleeve Valve "Down"When the ECM turns the oil pressure switching valve OFF, no oil pressure is applied to the lower portion of the sleeve valve. The oil pressure of the oil pump pushes the sleeve valve downward while compressing the relief valve spring together with the relief valve. Consequently, the oil passage provided on the side of the sleeve valve is moved downward as well. As a result, the opening pressure of the relief valve increases and the engine oil pressure is controlled to a high level.[Reference Oil Pressure]120 to 430 kPa (1.2 to 4.4 kgf/cm2, 17 to 62 psi)Relief valve spring is compressed by sleeve valveFrom Oil Pan
18 Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) New DTCsDTCDetection ItemTrouble AreaMemoryP0522Engine Oil Pressure Sensor / Switch Low• Open or short in oil pressure sender gauge assembly circuit• Oil pressure sender gauge assembly• ECMComes onstoredP0523Engine Oil Pressure Sensor / Switch High• Short in oil pressure sender gauge assembly circuitP0524Engine Oil Pressure Too Low• Oil pressure switching valve assemblyP06DAEngine Oil Pressure Control Circuit Open• Open or short in oil pressure switching valve assembly control circuit-P06DBEngine Oil Pressure Control Circuit LowP06DCEngine Oil Pressure Control Circuit High• Short in oil pressure switching valve assembly control circuit
19 DTC Detection Condition Lubrication SystemOil Pump (Electrically Variable Oil Pressure Type)DTC Detection ConditionDTCDTC Detection ConditionP0522Oil pressure sender gauge assembly output voltage is 0.04V or less.(2 trip detection logic)P0523Oil pressure sender gauge assembly output voltage is 4.7V or more.P0524Battery voltage is 11V or more and oil pressure is less than 140 to 270 kPa, and oil pressure switching valve assembly is turned from on to off and remains off for 1 second. (1 trip detection logic)P06DAOpen or short in oil pressure switching valve assembly control circuit.(1 trip detection logic)P06DBGround short or open in oil pressure switching valve assembly control circuit for 2 seconds or more. (1 trip detection trip)P06DCBattery short in oil pressure switching valve assembly control circuit for 3 seconds or more. (1 trip detection trip)
20 Lubrication System Service Point Engine Oil Pressure Control Check Oil pressure switching valve is forcibly operated by using the intelligent testerTester Menu: Powertrain > Engine and ECT > Utility > Engine Oil Pressure Control CheckHINT:This check requires the following vehicle conditions.Engine is idling and warm it up.Vehicle is stopped.Acceleration pedal is not depressed.Shift position is in Neutral.During this check, the engine speed will increase (Approx. 2,000 rpm) and the oil pressure switching valve will switch automatically.- Oil pressure switching valve cannot be switched manually.NOTE: Perform this check when DTC P0524 is output.
21 Lubrication SystemService PointEngine Oil Pressure Control Check
22 Oil Pressure Switching Valve Lubrication SystemService PointEngine Oil Pressure Control CheckVehicle operation during this checkActive Test StartActive Test FinishHighOil PressureLowONOil Pressure Switching Valve5 Sec.5 Sec.5 Sec.OFFDuring this check, the engine speed will increase (Approx rpm) and the oil pressure switching valve will switch automatically.Engine Speed [rpm]2,000IdleTime
23 Lubrication System Service Point Engine Oil Pressure Control Check Reference oil pressureItemSpecified ConditionValve Off (High Pressure Control Mode)120 to 430 kPaValve On (Low Pressure Control Mode)80 to 180 kPaDifference between high pressure control mode and low pressure control mode24.5 kPa or higherOil pressure is measured for 1 sec. when the valve is operated, and the value measured every 0.1 sec. is displayed for each valve state.
24 Lubrication System Service Point Engine Oil Pressure Control Check (Not Using Tester)Standard oil pressureMeasurement ResultsEngine ConditionSpecified ConditionIdling24.5 kPa or higherEngine running at 3,200 rpm150 kPa or higherEngine ConditionResult 1Result 2IdlingNormalAbnormalEngine running at 3,200 rpmOil pressure control stuck in low oil pressure control modeClogging in an oil line (oil strainer, etc.), or a problem with the oil pumpHINT:When not using the intelligent tester, it is not possible to determine whether the system is stuck in high oil pressure control mode.
25 Cooling System Overall A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature distribution in the cooling systemCoolant TypeCapacityToyota Super Long Life Coolantw/o Combustion Type Power Heater4.9 litersw/ Combustion Type Power Heater5.3 liters
26 Cooling System Parts Location Water Pump Radiator Reservoir Tank ThermostatWater InletRadiator Assembly
27 Cooling System Coolant Passages To Heater Core To Radiator Assembly From EGR CoolerFrom Heater CoreTo EGR CoolerFrom Radiator Reservoir TankFrom Radiator Assembly
28 Cooling System Coolant Passage After warm-up circulation A bypass valve is located on the water inlet housingThe coolant circulation system has been changed so that coolant only flows through the reservoir tank after the engine has warmed up.The coolant circulation system has been changed so that coolant flows from the reservoir tank to the upstream side of the thermostat instead of to the downstream side, thereby reducing the amount of cold coolant flowing while the engine is warming up. By doing this, engine warm-up performance has been increased and fuel economy has been improved.
29 Fuel System Overall A Common-rail Type Fuel Injection System is Used A 7-hole piezo type injector is usedSupply PumpCompensation Value and Data Matrix Code (DMC) Printed Piezo Type InjectorFuel Sender Gauge AssemblyFuel FilterInjectorCommon-rail Type Fuel Injection SystemCommon-rail
30 Emission Control System OverallA butterfly type EGR valve, in which the drive is controlled by the DC motor, is usedA bypass with an EGR cooler bypass switching valve is added to the EGR coolerWater-cooled Type EGR Cooler with Bypass Switching ValveDC Motor Type EGR Valve
31 Emission Control System Parts LocationNo. 2 EGR Valve AssemblyEGR Cooler Switching ValveElectric EGR Control Valve AssemblyAir Fuel Ratio SensorDifferential Pressure SensorFrontEGR w/Cooler Pipe AssemblyFrontFront Exhaust Gas Temperature SensorOxidation Catalytic ConverterRear Exhaust Gas Temperature SensorDPF Catalytic Converter
32 Emission Control System Catalyst support controlWhen the PM accumulation limit is surpassed, DPF indicator or message is displayed to prompt the driver to either drive at a constant speed or take the vehicle to a dealerWarning Indicator / Warning MessageVehicle ConditionsDPF Indicator Light*11st Phase(Illuminate)When PM regeneration control was not performed for a certain period. (Decides the calculated PM accumulation)2nd Phase(Blinking)When a predetermined PM accumulation is reached after 1st phase.MIL3rd Phase (Illuminate)When vehicle keeps driving without PM regeneration control after 2nd phase.- DTC P2463 is stored and MIL comes on (Replacement of the DPF might be required).The following text is coming from the owners manual■If the DPF system warning light comes on (diesel engine only)The deposit collected in the filter needs to be regenerated.The filter can be made to regenerate by driving in 3rd or higher gear ataround 60 km/h (36 mph) for approximately 20 minutes*. It can be alsomade to regenerate by normal driving at an engine speed of 2000 rpm orhigher for approximately 20 minutes*. The DPF system warning light willextinguish when regeneration is complete. If the regeneration is not completeafter driving for 45 minutes, the warning light will turn off once. (In thiscase, the warning light may turn on again.) If the above mentioned drivingcannot be carried out, or if the light does not extinguish even after driving,have the vehicle inspected by any authorized Toyota dealer or repairer, oranother duly qualified and equipped professional immediately.Malfunction indicator lightIf you continue driving while the DPF system warning light is flashing, themalfunction indicator light will illuminate. In this event, damage may becaused to the vehicle or an accident may occur. Have the vehicle inspectedby any authorized Toyota dealer or repairer, or another duly qualified andequipped professional, immediately.NOTICE■DPF warning lightIf you continuously drive for short distances, the DPF warning light may flashor illuminate. In this event, have the vehicle inspected by any authorizedToyota dealer or repairer, or another duly qualified and equipped professional,immediately.■To prevent the DPF system from failing●Do not drive for long periods of time while the DPF system warning light isflashing●Do not use fuel other than the specified type●Do not use engine oil other than the recommended type●Do not modify the exhaust pipe
33 Engine Control System Overall Non-contact Throttle Position Sensor ECMNon-contact Throttle Position SensorNon-contact Accelerator Pedal Position SensorAccelerator Pedal Position Sensor
34 Engine Control System Parts Location Actuator for Turbocharger – Nozzle Vane Position Sensor– DC MotorCam Position SensorFuel Injector AssemblyMetering UnitFuel Pressure SensorFuel Temperature SensorGlow PlugEngine Coolant Temperature SensorTurbo Pressure SensorFuel Pressure RegulatorCrank Position SensorThrottle Body– Throttle Position Sensor– Throttle Control MotorEngine Oil Level Sensor– Oil Lower Level Switch– Oil Upper Level Switch
35 Engine Control System Main Components Components Outline Quantity Atmospheric Temperature SensorThermistor Type1Air Flow MeterHot-wire Type (Digital Signal Type)Crank Position Sensor (Rotor Teeth)Pickup Coil Type (60-2)Cam Position Sensor (Rotor Teeth)Pick-up Coil Type (1)Engine Coolant Temperature SensorAccelerator Pedal SensorNon-contact TypeThrottle Position SensorInjectorPiezo Type (7-hole Type)4Turbo Pressure SensorSemiconductor Silicon Chip TypeIntake Air Temperature SensorFuel Pressure SensorSemiconductor Strain Gauge TypeFuel Temperature SensorEngine Oil Level SensorON/OFF Switch Type
36 Engine Control System System Control Table [1/2] System Outline Fuel Injection Volume ControlBased on the signals received from the various sensors, the ECM determines the fuel injection volume in accordance with the engine condition.Fuel Injection Timing ControlBased on the signals received from the various sensors, the ECM determines the fuel injection timing in accordance with the engine condition.Fuel Pressure ControlBased on the signals received from the various sensors, the ECM determines the fuel pressure via the metering unit and fuel pressure regulator in accordance with the engine condition.Idle Speed ControlThe ECM determines the idle speed in accordance with the engine condition, and controls the fuel injection volume in order to maintain the target idle speed.Pilot Injection ControlBased on the signals received from the various sensors, the ECM determines pilot injection volume, timing, and interval (between pilot injection and main injection) in accordance with the engine condition.Glow Plug ControlControls the length of time when the current is applied to the glow plugs, in accordance with the engine coolant temperature.Turbocharger ControlBased on signals from the various sensors, the ECM controls the turbocharger in accordance with engine condition by adjusting the nozzle vane.
37 Engine Control System System Control Table [2/2] System Outline Intake Throttle ControlBased on the signals received from the various sensors, the ECM determines throttle position in accordance with engine condition.Fully closes the diesel throttle control valve in order to reduce the vibration when the engine is stopped.Cooling Fan ControlCooling fan operation is controlled by signals from the ECM based on the coolant temperature, air conditioning condition*1.Air Conditioning Cut-off Control*1By turning the air conditioning compressor on or off in accordance with the engine condition, drivability is maintained.Starter Control(Cranking Hold Function)*2Once the engine switch is pushed, this control continues to operate the starter until the engine is started.Engine ImmobiliserProhibits fuel injection if an attempt is made to start the engine with an invalid ignition key.Oil Maintenance Management SystemWhen the ECM determines that the engine oil has deteriorated, when the engine oil level sensor detects that the engine oil level has increased, or when the running distance exceeds a predetermined value, the engine oil change reminder indicator light turns on to inform the driver of it.Brake Override SystemWhen the brake pedal is depressed while driving with the accelerator pedal depressing, this system may restrain the engine output and support brake performance*1: Models with air conditioning*2: Models with entry and start system
38 Engine Control System Service Point Initialization and Registration When ECM and/or other component(s), mentioned below are replaced, perform the following utility itemsUtility ItemReplacement PartECMInjectorA/F SensorDPF CatalystEngine AssemblyInaccessibleLearning ValuesSave / WriteOInjector CompensationPilot Quantity Learning Value ResetDPF Deterioration Record ClearA/F Sensor Compensation ResetVehicle Mileage Write
39 Engine Control System Service Point Initialization and Registration Function of utility itemsUtility ItemFunctionLearning ValuesSaveThis function can record all compensation values, learning values except supply pump discharge volume variancesWriteWriting saved data from intelligent tester to ECMInjector CompensationInputs injector compensation code manuallyNOTE: Function of read compensation code is discontinuedPilot Quantity Learning Value ResetLearns pilot injection quantity variancesDPF Deterioration Record ClearClears catalyst record of DPF thermal deteriorationNOTE: Function of catalyst record transferring (Read catalyst record and set catalyst record) is discontinuedA/F Sensor Compensation ResetClears air fuel ratio sensor compensation value used for EGR valve controlVehicle Mileage WriteIf Pilot Quantity Learning Values and DPF Deterioration Record cannot be saved or written using the intelligent tester, the ECM estimates the Pilot Quantity Learning Values and DPF Deterioration Record based on the traveled distance using this function.
40 Engine Control System Brake Override System General When the brake pedal is depressed while driving with the accelerator pedal depressing, this system may restrain the engine output and support brake performanceAccelerator pedal is depressedBoth pedals are depressedRestrain the engine outputEngine OutputRestraintTimeSystem Start
41 Engine Control System Brake Override System System Diagram ECM Accelerator Pedal PositionAccelerator Pedal Position SensorECMBrake Pedal OperationThis system decreases the accelerator pedal position value used for the engine output control to a predetermined valueStop Light SwitchVehicle SpeedVehicle Speed SensorsorWheel Speed SensorEDUInjectors
42 Engine Control System Brake Override System Operation Start Condition NoAccelerator pedal position is more than predetermined valueYesNoBrake pedal is depressed (Stop Light Switch: OFF ON)YesNoVehicle is decelerating (Deceleration Judgment is ON)*YesNoVehicle speed is more than predetermined valueYesEngine output by actual accelerator pedal positionEngine OutputRestraintIf the accelerator pedal is depressed while the brake pedal depressing, this system does not operate.Vehicle deceleration is calculated from vehicle speed signal.TimeOperation start conditions are met*: There is a case that the deceleration judgment is not performed according to the conditions of accelerator pedal position and vehicle speed
43 Accelerator Pedal Position Engine Control SystemBrake Override SystemDeceleration JudgmentThe deceleration judgment is used in order to judge the deceleration intention of the customer surelyFully DepressedThe system operates only by the stop light switch ON(Deceleration judgment is not used)The system operates by the stop light switch ON and deceleration judgment is ON (= vehicle is decelerating)Accelerator Pedal PositionIn the area that might not be able to be decelerated even if the customer depresses the brake pedal, the deceleration judgment is not used.Inoperative(Operation start conditions are not met)Released
44 Engine Control System Brake Override System Operation Stop Condition Operation start conditions are metEngine OutputRestraintTimeBrake pedal is released (Stop Light Switch: ON OFF)orAccelerator pedal is depressed or releasedNoYesEngine OutputReturnTimeOperation stop condition is met