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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

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

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 (HP) @ rpm] 73 (98) @ 5200 57 (76) @ 5000 Max. Torque [N·m (ft·lbf) @ rpm] 142 (105) @ 4000 111 (82) @ 4200 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

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

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

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

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

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

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

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)

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)

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

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: 09276-75010 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

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

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

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 15000 km / 9000 miles or 12 months Severe Condition Replace at every 7500 km / 4500 miles or 6 months Australia, Mexico, Taiwan Replace at every 10000 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 15000 km / 9000 miles or 12 months [Severe] Replace at every 7500 km / 4500 miles or 6 months Australia / Taiwan / Mexico [Normal] Replace at every 10000 km / 6000 miles or 12 months [Severe] Replace at every 5000 km / 3000 miles or 6 months Instructor & Technical Staff

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

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

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

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

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

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

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

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

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

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

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

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

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

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.)

Service Point (Ignition System) New M0del PRIUS 2009 Service Point (Ignition System) Spark Plug Recommend tools Spark Plug Wrench 14 mm (09011-3C220) [Spark Plug Removal] Compression Gauge Compression Gauge Adapter [Compression Inspection] Instructor & Technical Staff

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

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

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

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

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