Verso-s1ND-TV gen3 Euro 5

2

Engine Overall1ND-TV Engine

1ND-TV1ND-TV

Engine 1ND-TV

No. of Cylinders and Arrangement

4-cylinder, In-line

Valve Mechanism8-valve SOHC,

Chain Drive

Combustion Chamber Direct Injection Type

Flow of Intake and Exhaust Gases

Cross-flow

Fuel System Common-rail Type

Displacement [cm3] 1,364

Bore x Stroke [mm] 73.0 x 81.5

Compression Ratio 16.5:1

Max. Output [kW @ rpm] 66 @ 3,800

Max. Torque [Nm @ rpm] 205 @ 1,800 to 2,800

Valve Timing

IntakeOpen 4º BTDC

Closed 36º ABDC

ExhaustOpen 44º BBDC

Closed 4º ATDC

Oil Grade ACEA C2

Fuel Cetane Number 48 or higher

Firing Order 1 –3 – 4 – 2

Emission Regulation EURO V

3

Engine OverallFeatures

Rocker Arm

Injector Supply Pump

•EGR Valve•EGR Cooler

Exhaust Manifold ConverterOil Pump (Electrically Variable Oil Pressure Type)

After Warm-up Circulation System

Common-rail

Throttle Body

Oil PumpOil Level Sensor

Oil Filter

Turbo Charger

Vacuum Pump

Oil Pressure Switching Valve

Oil Pressure Sender Gage Assembly

• Cranking Hold Function• Brake Override System

4

Engine OverallSpecifications

Model Verso-s Urban Cruiser

No. of Cylinders and Arrangement

4-Cylinder, In-line

Valve Mechanism8-Valve SOHC, Chain

Drive

Combustion Chamber Direct Injection Type

Fuel System Common-rail Type

Displacement [cm3] 1,364

Bore x Stroke [mm] 73.0 X 81.5

Compression Ratio 16.5 : 1

Maximum Output (EEC) [kW @ rpm]

66 @ 3,800

Maximum Torque (EEC) [N·m @ rpm]

205 @ 1,800 to 2,800

Valve Timing

IntakeOpen 4º BTDC

Close 36º ABDC

ExhaustOpen 44º BBDC

Close 4º ATDC

Firing Order 1 – 3 – 4 - 2

Emission Regulation EURO V Euro IV

Engine Oil

Viscosity / Grade0W-30 or 5W-30 /ACEA

C2

6

Engine OverallMain Features [2/2]

Item FeatureAchieved

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 SystemA 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)

11

Lubrication System

Oil Grade ACEA 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 Fill 4.5 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

13

Lubrication SystemOil 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

Pre

ssure

[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

Lubrication SystemOil Pump (Electrically Variable Oil Pressure Type)

• Parts Location

Oil Pump Assembly

Oil Pressure Switching Valve

Oil Pressure Sender Gage Assembly

15

Lubrication SystemOil Pump (Electrically Variable Oil Pressure Type)

• System DiagramEngine Coolant Temperature Sensor

Crankshaft Position Sensor

Engine Oil Level Sensor

Accelerator Pedal Assembly

THW

NE

OILH

VPA

VPA2

Oil Pressure SenderGauge Assembly

POP

Engine Coolant Temperature Sensor SignalCrankshaft Position Sensor SignalEngine Oil Level Sensor SignalAccelerator Pedal Position Sensor SignalAccelerator Pedal Position Sensor SignalOil Pressure Sender Gauge SignalOil Pressure Switching Valve Operation Signal

THW:NE:

OILH:VPA:

VPA2:POP:V2O:

Oil Pressure Switching

Valve Assembly

V2O

ECM

ON / OFF

16

Lubrication System

Engine Speed [rpm]

Oil

Pre

ssure

[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

Lubrication System

Engine Speed [rpm]

Oil

Pre

ssure

[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

Oil Pump (Electrically Variable Oil Pressure Type)

• New DTCsDTC Detection Item Trouble Area Memory

P0522

Engine Oil Pressure Sensor /

Switch Low

• Open or short in oil pressure sender gauge assembly circuit

• Oil pressure sender gauge assembly• ECM

Comes on

stored

P0523

Engine Oil Pressure Sensor /

Switch High

• Short in oil pressure sender gauge assembly circuit

• Oil pressure sender gauge assembly• ECM

Comes on

stored

P0524

Engine Oil Pressure Too Low

• Oil pressure sender gauge assembly• Oil pressure switching valve assembly• ECM

Comes on

stored

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

DTC DTC Detection Condition

P0522Oil 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. (2 trip detection logic)

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)

Lubrication SystemOil Pump (Electrically Variable Oil Pressure Type)

• DTC Detection Condition

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

Lubrication SystemService Point

• Engine Oil Pressure Control Check

22

Lubrication SystemService 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. 5 Sec. 5 Sec.

Active Test Finish

23

Lubrication SystemService 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

Lubrication System

Engine Condition Specified Condition

Idling 24.5 kPa or higher

Engine running at 3,200 rpm 150 kPa or higher

Engine Condition Result 1 Result 2

Idling Normal Abnormal

Engine running at 3,200 rpm Abnormal Abnormal

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

Cooling SystemOverall

• A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature distribution in the cooling system

Coolant Type Capacity

Toyota Super Long Life Coolant

w/o Combustion Type Power

Heater4.9 liters

w/ Combustion Type Power

Heater5.3 liters

26

Cooling SystemParts Location

Radiator Assembly

Water Pump

Thermostat

Water Inlet

Radiator Reservoir Tank

27

Cooling SystemCoolant Passages

From Radiator Reservoir Tank

From Radiator Assembly

To EGR Cooler

From Heater Core

From EGR Cooler

To Radiator Assembly

To Heater Core

28

Cooling SystemCoolant Passage

• After warm-up circulation A bypass valve is located on the water inlet housing

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 Message

Vehicle 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.

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).

37

Engine Control SystemSystem Control Table [2/2]

System Outline

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 ControlCooling 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 ImmobiliserProhibits 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 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 SystemService Point

• Initialization and Registration When ECM and/or other component(s), mentioned

below are replaced, perform the following utility items

Utility Item

Replacement Part

ECMInjector

A/F Sensor

DPF Catalys

t

Engine AssemblyInaccessibl

e

Learning ValuesSave / Write

O

Injector Compensation

O O O

Pilot Quantity Learning Value

ResetO O

DPF Deterioration Record Clear

O

A/F Sensor Compensation

ResetO

Vehicle Mileage Write

O

39

Engine Control SystemService Point

• Initialization and Registration Function of utility items

Utility Item Function

Learning

Values

SaveThis function can record all compensation values, learning values except supply pump discharge volume variances

Write Writing saved data from intelligent tester to ECM

Injector Compensation

Inputs injector compensation code manuallyNOTE: Function of read compensation code is discontinued

Pilot Quantity Learning Value

ResetLearns pilot injection quantity variances

DPF Deterioration Record Clear

Clears catalyst record of DPF thermal deteriorationNOTE: 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.