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1 Verso-s 1ND-TV gen3 Euro 5. 2 Engine Overall 1ND-TV Engine 1ND-TV Engine1ND-TV No. of Cylinders and Arrangement4-cylinder, In-line Valve Mechanism 8-valve.

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Presentation on theme: "1 Verso-s 1ND-TV gen3 Euro 5. 2 Engine Overall 1ND-TV Engine 1ND-TV Engine1ND-TV No. of Cylinders and Arrangement4-cylinder, In-line Valve Mechanism 8-valve."— Presentation transcript:

1 1 Verso-s 1ND-TV gen3 Euro 5

2 2 Engine Overall 1ND-TV Engine 1ND-TV Engine1ND-TV No. of Cylinders and Arrangement4-cylinder, In-line Valve Mechanism 8-valve SOHC, Chain Drive Combustion ChamberDirect Injection Type Flow of Intake and Exhaust GasesCross-flow Fuel SystemCommon-rail Type Displacement [cm 3 ]1,364 Bore x Stroke [mm]73.0 x 81.5 Compression Ratio16.5:1 Max. Output [kW @ rpm]66 @ 3,800 Max. Torque [N  m @ rpm]205 @ 1,800 to 2,800 Valve Timing Intake Open4º BTDC Closed36º ABDC Exhaust Open44º BBDC Closed4º ATDC Oil GradeACEA C2 Fuel Cetane Number48 or higher Firing Order1 –3 – 4 – 2 Emission RegulationEURO V

3 3 Engine Overall Features Rocker Arm Injector Supply Pump EGR Valve EGR Cooler Exhaust Manifold Converter Oil Pump (Electrically Variable Oil Pressure Type) After Warm-up Circulation System Common-rail Throttle Body Oil Pump Oil Level Sensor Oil Filter Turbo Charger Vacuum Pump Oil Pressure Switching Valve Oil Pressure Sender Gage Assembly Cranking Hold Function Brake Override System

4 4 Engine Overall Specifications ModelVerso-sUrban Cruiser No. of Cylinders and Arrangement4-Cylinder, In-line  Valve Mechanism8-Valve SOHC, Chain Drive  Combustion ChamberDirect Injection Type  Fuel SystemCommon-rail Type  Displacement [cm 3 ]1,364  Bore x Stroke [mm]73.0 X 81.5  Compression Ratio16.5 : 1  Maximum Output (EEC) [kW @ rpm]66 @ 3,800  Maximum Torque (EEC) [N·m @ rpm]205 @ 1,800 to 2,800  Valve Timing Intake Open4º BTDC  Close36º ABDC  Exhaust Open44º BBDC  Close4º ATDC  Firing Order1 – 3 – 4 - 2  Emission RegulationEURO VEuro IV Engine OilViscosity / Grade0W-30 or 5W-30 /ACEA C2 

5 5 Engine Overall Main Features [1/2] ItemFeature Achieved Performance Engine Proper A 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 System An 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 Used (1), (5) Exhaust System The Exhaust Manifold Converter Uses Oxidation Catalyst(5) The DPF Catalytic Converter is Used(5) A 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 6 Engine Overall Main Features [2/2] ItemFeature Achieved Performance Lubrication System An 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 System TOYOTA Genuine Super Long Life Coolant (SLLC) is Used(4) After Warm-up Circulation System is Used(1), (5) Fuel System A Common-rail Type Fuel Injection System is Used(1), (2), (5) Compensation Value and Data Matrix Code (DMC) Printed Piezo Type Injector is Used (1), (2), (5) Emission Control System A DC Motor Type EGR Valve is Used(1), (5) A Water-cooled Type EGR Cooler with Bypass Switching Valve is Used (1), (5) Engine Control System An 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 Used(5) A Pilot Injection Control is Used(1), (2), (5) A Oil Maintenance Management System is Used(4) Brake Override System is Used(1)

7 7 Engine Overall Engine Serial Number

8 8 Intake System Overall A DC motor type throttle body is used A variable nozzle vane type turbocharger driven by a DC motor is used Turbocharger Diesel Throttle

9 9 Intake System Parts Location DC Motor Type Diesel Throttle DC Motor Type VN (Variable Nozzle) Vane Turbocharger

10 10 Exhaust System Exhaust Manifold Converter Uses Oxidation Catalyst DPF Catalytic Converter Front Exhaust Pipe Assembly Main Muffler Exhaust Manifold Converter Overall A stainless steel exhaust manifold and exhaust pipe are used for weight reduction and proper rust resistance

11 11 Lubrication System Oil GradeACEA C2 Oil Viscosity (Preferred)0W-30 or 5W-30 Drain and Refill w/ Oil Filter Change 4.1 liters w/o Oil Filter Change 3.6 liters Dry Fill4.5 liters Type of Engine Oil FilterReplaceable Element Type Overall Lubrication circuit is fully pressurized and oil passes through oil filter An 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

12 12 Lubrication System Oil Filter Element Replacement Type Oil Filter is Used Oil Filter Cap Oil Filter Element Oil Filter Bracket (Aluminum)

13 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 efficiency Engine Speed [rpm] Oil Pressure [kPa] Opening Pressure of Piston Oil Jet From Oil Pan To Engine Parts Oil Pump Oil Pressure Switching Valve Sleeve Valve Relief Valve Relief Valve Spring

14 14 Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) Parts Location Oil Pump Assembly Oil Pressure Switching Valve Oil Pressure Sender Gage Assembly

15 15 Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) System Diagram Engine Coolant Temperature Sensor Crankshaft Position Sensor Engine Oil Level Sensor Accelerator Pedal Assembly THW NE OILH VPA VPA2 Oil Pressure Sender Gauge Assembly POP Engine Coolant Temperature Sensor Signal Crankshaft Position Sensor Signal Engine Oil Level Sensor Signal Accelerator Pedal Position Sensor Signal Oil Pressure Sender Gauge Signal Oil Pressure Switching Valve Operation Signal THW: NE: OILH: VPA: VPA2: POP: V2O: Oil Pressure Switching Valve Assembly V2O ECM ON / OFF

16 16 Lubrication System Engine Speed [rpm] Oil Pressure [kPa] Opening Pressure of Piston Oil Jet From Oil Pan To Engine Parts ON Sleeve Valve "Rise" Open Oil 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 decreases

17 17 Lubrication System Engine Speed [rpm] Oil Pressure [kPa] Opening Pressure of Piston Oil Jet From Oil Pan To Engine Parts OFF Sleeve Valve "Down" Close Relief valve spring is compressed by sleeve valve 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 increases

18 18 Oil Pump (Electrically Variable Oil Pressure Type) New DTCs DTCDetection ItemTrouble AreaMemory P0522 Engine Oil Pressure Sensor / Switch Low Open or short in oil pressure sender gauge assembly circuit Oil pressure sender gauge assembly ECM Comes onstored P0523 Engine Oil Pressure Sensor / Switch High Short in oil pressure sender gauge assembly circuit Oil pressure sender gauge assembly ECM Comes onstored P0524 Engine Oil Pressure Too Low Oil pressure sender gauge assembly Oil pressure switching valve assembly ECM Comes onstored P06DA Engine Oil Pressure Control Circuit Open Open or short in oil pressure switching valve assembly control circuit Oil pressure switching valve assembly ECM -stored P06DB Engine Oil Pressure Control Circuit Low Open or short in oil pressure switching valve assembly control circuit Oil pressure switching valve assembly ECM -stored P06DC Engine Oil Pressure Control Circuit High Short in oil pressure switching valve assembly control circuit Oil pressure switching valve assembly ECM -stored Lubrication System

19 19 DTCDTC Detection Condition P0522 Oil pressure sender gauge assembly output voltage is 0.04V or less. (2 trip detection logic) P0523 Oil pressure sender gauge assembly output voltage is 4.7V or more. (2 trip detection logic) P0524 Battery 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) P06DA Open or short in oil pressure switching valve assembly control circuit. (1 trip detection logic) P06DB Ground short or open in oil pressure switching valve assembly control circuit for 2 seconds or more. (1 trip detection trip) P06DC Battery short in oil pressure switching valve assembly control circuit for 3 seconds or more. (1 trip detection trip) Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) DTC Detection Condition

20 20 Lubrication System NOTE: Perform this check when DTC P0524 is output. HINT: 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. Service Point Engine Oil Pressure Control Check  Oil pressure switching valve is forcibly operated by using the intelligent tester Tester Menu: Powertrain > Engine and ECT > Utility > Engine Oil Pressure Control Check

21 21 Lubrication System Service Point Engine Oil Pressure Control Check

22 22 Lubrication System Service Point Engine Oil Pressure Control Check  Vehicle operation during this check Engine Speed [rpm] Oil Pressure Time Oil Pressure Switching Valve Idle Active Test Start ON OFF High Low 2,000 5 Sec. Active Test Finish

23 23 Lubrication System Service Point Engine Oil Pressure Control Check  Reference oil pressure ItemSpecified Condition Valve Off (High Pressure Control Mode) 120 to 430 kPa Valve On (Low Pressure Control Mode) 80 to 180 kPa Difference between high pressure control mode and low pressure control mode 24.5 kPa or higher Oil 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 24 Lubrication System Engine ConditionSpecified Condition Idling24.5 kPa or higher Engine running at 3,200 rpm150 kPa or higher Engine ConditionResult 1Result 2 IdlingNormalAbnormal Engine running at 3,200 rpmAbnormal HINT: When not using the intelligent tester, it is not possible to determine whether the system is stuck in high oil pressure control mode. Oil pressure control stuck in low oil pressure control mode Clogging in an oil line (oil strainer, etc.), or a problem with the oil pump Service Point Engine Oil Pressure Control Check (Not Using Tester)  Standard oil pressure  Measurement Results

25 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 system Coolant TypeCapacity Toyota Super Long Life Coolant w/o Combustion Type Power Heater 4.9 liters w/ Combustion Type Power Heater 5.3 liters

26 26 Cooling System Parts Location Radiator Assembly Water Pump Thermostat Water Inlet Radiator Reservoir Tank

27 27 Cooling System Coolant Passages From Radiator Reservoir Tank From Radiator Assembly To EGR Cooler From Heater Core From EGR Cooler To Radiator Assembly To Heater Core

28 28 Cooling System Coolant Passage After warm-up circulation  A bypass valve is located on the water inlet housing

29 29 Fuel System Overall A Common-rail Type Fuel Injection System is Used A 7-hole piezo type injector is used Compensation Value and Data Matrix Code (DMC) Printed Piezo Type Injector Common-rail Type Fuel Injection System Common-rail Injector Fuel Sender Gauge Assembly Fuel Filter Supply Pump

30 30 Emission Control System Overall A butterfly type EGR valve, in which the drive is controlled by the DC motor, is used A bypass with an EGR cooler bypass switching valve is added to the EGR cooler DC Motor Type EGR Valve Water-cooled Type EGR Cooler with Bypass Switching Valve

31 31 Emission Control System Parts Location Electric EGR Control Valve Assembly EGR Cooler Switching Valve No. 2 EGR Valve Assembly Differential Pressure Sensor EGR w/Cooler Pipe Assembly Front Exhaust Gas Temperature Sensor Rear Exhaust Gas Temperature Sensor Oxidation Catalytic Converter DPF Catalytic Converter Air Fuel Ratio Sensor Front

32 32 Emission Control System Catalyst support control When 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 dealer Warning Indicator / Warning MessageVehicle Conditions DPF Indicator Light* 1 1st Phase (Illuminate) When PM regeneration control was not performed for a certain period. (Decides the calculated PM accumulation) DPF Indicator Light* 1 2nd Phase (Blinking) When a predetermined PM accumulation is reached after 1st phase. MIL 3rd Phase (Illuminate) When vehicle keeps driving without PM regeneration control after 2 nd phase. - DTC P2463 is stored and MIL comes on (Replacement of the DPF might be required).

33 33 Engine Control System Overall Non-contact Accelerator Pedal Position Sensor Non-contact Throttle Position Sensor Accelerator Pedal Position Sensor ECM

34 34 Engine Control System Parts Location Turbo Pressure Sensor Fuel Pressure Sensor Fuel Injector Assembly Cam Position Sensor Glow Plug Actuator for Turbocharger – Nozzle Vane Position Sensor – DC Motor Metering Unit Fuel Temperature Sensor Engine Coolant Temperature Sensor Fuel Pressure Regulator Crank Position Sensor Engine Oil Level Sensor – Oil Lower Level Switch – Oil Upper Level Switch Throttle Body – Throttle Position Sensor – Throttle Control Motor

35 35 Engine Control System Main Components ComponentsOutlineQuantity Atmospheric Temperature SensorThermistor Type1 Air Flow MeterHot-wire Type (Digital Signal Type)1 Crank Position Sensor (Rotor Teeth)Pickup Coil Type (60-2)1 Cam Position Sensor (Rotor Teeth)Pick-up Coil Type (1)1 Engine Coolant Temperature SensorThermistor Type1 Accelerator Pedal SensorNon-contact Type1 Throttle Position SensorNon-contact Type1 InjectorPiezo Type (7-hole Type)4 Turbo Pressure SensorSemiconductor Silicon Chip Type1 Intake Air Temperature SensorThermistor Type1 Fuel Pressure SensorSemiconductor Strain Gauge Type1 Fuel Temperature SensorThermistor Type1 Engine Oil Level SensorON/OFF Switch Type1

36 36 Engine Control System System Control Table [1/2] SystemOutline Fuel Injection Volume Control Based on the signals received from the various sensors, the ECM determines the fuel injection volume in accordance with the engine condition. Fuel Injection Timing Control Based on the signals received from the various sensors, the ECM determines the fuel injection timing in accordance with the engine condition. Fuel Pressure Control Based 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 Control The 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 Control Based 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 Control Controls the length of time when the current is applied to the glow plugs, in accordance with the engine coolant temperature. Turbocharger Control Based on signals from the various sensors, the ECM controls the turbocharger in accordance with engine condition by adjusting the nozzle vane.

37 37 Engine Control System System Control Table [2/2] SystemOutline Intake Throttle Control Based 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 Control Cooling fan operation is controlled by signals from the ECM based on the coolant temperature, air conditioning condition*1. Air Conditioning Cut-off Control*1 By turning the air conditioning compressor on or off in accordance with the engine condition, drivability is maintained. Starter Control (Cranking Hold Function)*2 Once the engine switch is pushed, this control continues to operate the starter until the engine is started. Engine Immobiliser Prohibits fuel injection if an attempt is made to start the engine with an invalid ignition key. Oil Maintenance Management System When 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 System When 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 38 Engine Control System Service Point Initialization and Registration  When ECM and/or other component(s), mentioned below are replaced, perform the following utility items Utility Item Replacement Part ECM Injector A/F Sensor DPF Catalyst Engine Assembly Inaccessible Learning Values Save / Write O Injector Compensation OOO Pilot Quantity Learning Value Reset OO DPF Deterioration Record Clear O A/F Sensor Compensation Reset O Vehicle Mileage WriteO

39 39 Engine Control System Service Point Initialization and Registration  Function of utility items Utility ItemFunction Learning Values Save This function can record all compensation values, learning values except supply pump discharge volume variances WriteWriting saved data from intelligent tester to ECM Injector Compensation Inputs injector compensation code manually NOTE: Function of read compensation code is discontinued Pilot Quantity Learning Value Reset Learns pilot injection quantity variances DPF Deterioration Record Clear Clears catalyst record of DPF thermal deterioration NOTE: Function of catalyst record transferring (Read catalyst record and set catalyst record) is discontinued A/F Sensor Compensation Reset Clears air fuel ratio sensor compensation value used for EGR valve control Vehicle Mileage Write If 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 40 Engine Control System Engine Output Time Restraint Accelerator pedal is depressed Both pedals are depressed Restrain the engine output System Start 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 performance

41 41 Engine Control System Brake Override System System Diagram Vehicle Speed Sensors Accelerator Pedal Position Sensor ECM Stop Light Switch Brake Pedal Operation Accelerator Pedal Position Vehicle Speed Wheel Speed Sensor or This system decreases the accelerator pedal position value used for the engine output control to a predetermined value EDU Injectors

42 42 Engine Control System Brake Override System Operation Start Condition Accelerator pedal position is more than predetermined value Brake pedal is depressed (Stop Light Switch: OFF  ON) Vehicle is decelerating (Deceleration Judgment is ON)* Vehicle speed is more than predetermined value Yes No Yes Engine Output Time Restraint Operation start conditions are met Engine output by actual accelerator pedal position *: There is a case that the deceleration judgment is not performed according to the conditions of accelerator pedal position and vehicle speed

43 43 Engine Control System Brake Override System Deceleration Judgment  The deceleration judgment is used in order to judge the deceleration intention of the customer surely Accelerator Pedal Position Released The system operates by the stop light switch ON and deceleration judgment is ON (= vehicle is decelerating) The system operates only by the stop light switch ON (Deceleration judgment is not used) Inoperative (Operation start conditions are not met) Fully Depressed

44 44 Engine Control System Brake Override System Operation Stop Condition Brake pedal is released (Stop Light Switch: ON  OFF) or Accelerator pedal is depressed or released No Yes Engine Output Time Return Operation stop condition is met Engine Output Time Restraint Operation start conditions are met


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