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Toyota 1NZ-FE, User Manual

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Toyota 1NZ-FE User Manual Download Page 13

ENGINE - 1NZ-FE ENGINE

00REG06Y

Exhaust Manifold

Intake Manifold

Air Cleaner

TWCs

Sub Muffler

Main
Muffler

EG-14

INTAKE AND EXHAUST SYSTEM

1. General

A plastic intake manifold is used for weight reduction.

The linkless-type throttle body is used to realize excellent throttle control.

ETCS-i (Electronic Throttle Control System-intelligent) provides excellent throttle control. For details,
see page EG-36.

The exhaust pipe uses a ball joint in order to achieve a simple construction and reliability.

Summary of Contents for 1NZ-FE

Page 1: ... a in line 4 cylinder 1 5 liter 16 valve DOHC engine The VVT i Variable Valve Timing intelligent system DIS Direct Ignition System and ETCS i Electronic Throttle Control System intelligent are used on this engine in order to realize high performance quietness fuel economy and clean emission ...

Page 2: ... 5 1 Max Output 1 SAE NET 79 kW 6000 rpm 106 HP 6000 rpm Max Torque 1 SAE NET 139 N m 4200 rpm 103 ft lbf 4200 rpm Intake Open 7 33 BTDC Valve Intake Close 52 12 ABDC Valve Timing Exhaust Open 42 BBDC g Exhaust Close 2 ATDC Firing Order 1 3 4 2 Research Octane Number 90 or higher Octane Rating 87 or higher Oil Grade ILSAC Tailpipe Emission Regulation TIRE2 ULEV II Evaporative Emission Regulation O...

Page 3: ...is used Intake and A stainless steel exhaust manifold is used Exhaust System Two TWCs Three Way Catalytic Converter are used A rearward exhaust layout is used to realize the early activation of the catalyst 12 hole type injector is used Fuel System The fuel returnless system is used Fuel System Quick connectors are used to connect the fuel hose with the fuel pipes The long reach type spark plugs a...

Page 4: ...and reduce exhaust emissions The routing of the water jacket in the cylinder head is optimized to achieve high cooling performance Through the use of the taper squish combustion chamber the engine s knocking resistance and fuel efficiency have been improved 2 Cylinder Block Lightweight aluminum alloy is used for the cylinder block Through the use of the offset crankshaft the bore center is shifted...

Page 5: ...r to enhance the adhesion between the liners and the aluminum cylinder block The enhanced adhesion helps improve heat dissipation resulting in a lower overall temperature and heat deformation of the cylinder bores 3 Piston The piston is made of aluminum alloy The piston head portion is used a taper squish shape to accomplish fuel combustion efficiency Semi floating type piston pins are used By inc...

Page 6: ...strength steel for weight reduction Nutless type plastic region tightening bolts are used for a light design 5 Crankshaft The diameter and width of the pins and journals have been reduced and the pins for the No 1 and No 4 cylinders have been made highly rigid to realize a lightweight and low friction performance The crankshaft has 5 journals and 4 balance weights A crankshaft position sensor roto...

Page 7: ... Adjusting valve lifters are available in 35 increments of 0 020 mm 0 0008 in from 5 060 mm 0 1992 in to 5 740 mm 0 2260 in For details refer to 2006 Yaris Repair Manual Pub No RM00R0U EG 8 VALVE MECHANISM 1 General The shimless type valve lifter is used to increase the amount of the valve lift The intake and exhaust camshafts are driven by a timing chain The VVT i system is used to realize fuel e...

Page 8: ...the intake camshaft to vary the timing of the intake valves A Timing rotor is provided behind the intake camshaft to trigger the camshaft position sensor 3 Timing Chain and Chain Tensioner A roller type timing chain with an 8 0 mm 0 315 in pitch is used to make the engine compact and reduce noise The timing chain is lubricated by an oil jet The chain tensioner uses a spring and oil pressure to mai...

Page 9: ...il Pump Back View EG 10 4 Timing Chain Cover A single piece aluminum diecast timing chain cover that entirely seals the front portion of the cylinder block and cylinder head is used A service hole for the chain tensioner is provided in the timing chain cover to improve serviceability ...

Page 10: ... LUBRICATION SYSTEM 1 General The lubrication circuit is fully pressurized and oil passes through an oil filter A trochoid gear type oil pump which is driven directly by the crankshaft is provided in the front of the cylinder block The oil filter is installed diagonally downward from the side of the cylinder block to realize excellent serviceability The intake camshaft is provided with a VVT i con...

Page 11: ... forced circulation type A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature distribution in the cooling system An aluminum radiator core is used for weight reduction The flow of the engine coolant makes a U turn in the cylinder block to ensure a smooth flow of the engine coolant A single cooling fan provides both the cooling and air conditioner ...

Page 12: ...o not use plain water alone Color Pink Capacity M T 4 8 5 1 4 2 Capacity Liters US qts Imp qts A T 4 7 5 0 4 1 Maintenance Intervals First Time 100 000 miles 160 000 km Maintenance Intervals Subsequent Every 50 000 miles 80 000 km Thermostat Opening Temperature C F 80 84 176 183 SLLC is pre mixed the U S A models 50 coolant and 50 deionized water the Canada models 55 coolant and 45 deionized water...

Page 13: ...al A plastic intake manifold is used for weight reduction The linkless type throttle body is used to realize excellent throttle control ETCS i Electronic Throttle Control System intelligent provides excellent throttle control For details see page EG 36 The exhaust pipe uses a ball joint in order to achieve a simple construction and reliability ...

Page 14: ...l filter which adsorbs the HC that accumulates in the intake system when the engine is stopped is used in the air cleaner cap in order to reduce evaporative emissions 3 Throttle Body The linkless type throttle body is used and it realizes excellent throttle control A DC motor with excellent response and minimal power consumption is used for the throttle control motor The ECM performs the duty rati...

Page 15: ... of heat transferred from the cylinder head As a result it has become possible to reduce the intake temperature and improve the intake volumetric efficiency A mesh type gasket is used in order to reduce the intake noise 5 Exhaust Pipe and Muffler A ball joint is used to joint the exhaust manifold to the exhaust front pipe and the exhaust front pipe to the exhaust tail pipe As a result a simple con...

Page 16: ...issions A fuel tank made of multi layer plastic is used A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed in a front or side collision For details see page EG 45 A quick connector is used to connect the fuel pipe with the fuel hose to realize excellent serviceability A compact 12 hole type injector is used to ensure the atomization of fuel The ORVR On Board Refueling...

Page 17: ...E High Density Polyethylene EG 18 2 Fuel Returnless System This system is used to reduce the evaporative emission As shown below integrating the fuel filter pressure regulator fuel sender gauge and fuel cutoff valve with module fuel pump assembly enables to discontinue the return of fuel from the engine area and prevent temperature rise inside the fuel tank 3 Fuel Tank Low permeability has been re...

Page 18: ...ct Ignition System is used The DIS in this engine is an independent ignition system which has one ignition coil for each cylinder The DIS ensures the ignition timing accuracy reduces high voltage loss and realizes the overall reliability of the ignition system by eliminating the distributor The spark plug caps which connect to the spark plugs are integrated with the ignition coils Also the igniter...

Page 19: ... be made thick Thus the water jacket can be extended near the combustion chamber which contributes to cooling performance Iridium tipped spark plugs are used to realize a 100 000 km 62 500 mile maintenance free operation By making the center electrode of iridium the same ignition performance as the platinum tipped type spark plug and excellent of durability have been realized Specification DENSO S...

Page 20: ... CHARGING SYSTEM A compact and lightweight segment conductor type generator that generates high amperage output in a highly efficient manner is used as standard equipment This generator has a joined segment conductor system in which multiple segment conductors are welded together to form the stator Compared to the conventional wiring system the electrical resistance is reduced due to the shape of ...

Page 21: ...ENGINE 1NZ FE ENGINE 00REG20Y Generator E Regulator B M IG S L Ignition Switch Discharge Warning Light EG 22 Wiring Diagram ...

Page 22: ...A PS planetary reduction segment conductor motor type starter is used in the models for Canada and cold areas of the U S A Specification Destination U S A Canada Cold Areas of U S A Starter Type P Type PS Type Rating Output 0 8 kW 1 6 kW Rating Voltage 12 V Length 1 mm in 154 6 1 133 5 2 Weight g lb 2800 6 2 Rotation Direction 2 Clockwise 1 Length from the mounted area to the rear end of the start...

Page 23: ...ditions that are realized by winding numerous round shaped conductor wires can be achieved without increasing the mass As a result the output torque has been increased and the armature coil has been made compact Because the surface of the square shaped conductors that are used in the armature coil functions as a commutator the overall length of the PS type starter has been shortened Instead of the...

Page 24: ...hen the airbag is deployed Air Fuel Ratio Sensor and Oxygen Sensor Heater Control Maintains the temperature of the air fuel ratio sensor or oxygen sensor at an appropriate level to realize accuracy of detection of the oxygen concentration in the exhaust gas Oxygen Sensor Heater Control Maintains the temperature of the oxygen sensor at an appropriate level to realize accuracy of detection of the ox...

Page 25: ...e is started Engine Immobilizer 2 Prohibits fuel delivery and ignition if an attempt is made to start the engine with an invalid ignition key Diagnosis See Page EG 59 When the ECM detects a malfunction the ECM diagnoses and memorizes the failed section Fail Safe See Page EG 59 When the ECM detects a malfunction the ECM stops or controls the engine according to the data already in memory 2 for Mode...

Page 26: ...XYGEN SENSOR Bank 1 Sensor 2 SFI No 1 INJECTOR No 2 INJECTOR No 3 INJECTOR No 4 INJECTOR ESA IGNITION COIL with IGNITER SPARK PLUGS VVT i CAMSHAFT TIMING OIL CONTROL VALVE ETCS i THROTTLE CONTROL MOTOR FUEL PUMP CONTROL CIRCUIT OPENING RELAY A F SENSOR OXYGEN SENSOR HEATER CONTROL A F SENSOR HEATER Bank 1 Sensor 1 OXYGEN SENSOR HEATER Bank 1 Sensor 2 VG THA NE G2 VTA1 VTA2 THW VPA VPA2 KNK1 IGSW S...

Page 27: ...APORATIVE EMISSION CONTROL CANISTER PUMP MODULE LEAK DETECTION PUMP VENT VALVE PURGE VSV STATER CONTROL STARTER RELAY ACC CUT RELAY COOLING FAN CONTROL COOLING FAN RELAY No 1 COOLING FAN RELAY No 2 EFI MAIN RELAY COMBNATION METER MIL PPMP ELS1 ELS3 STP ALT 3 IMI IMO TC CANH CANL BATT MPMP VPMP PRG STAR ACCR FAN L FAN H MREL B W ECM EG 28 2 for Models with Engine Immobilizer System 3 for Models wit...

Page 28: ...r Flow Meter Intake Air Temperature Sensor Camshaft Position Sensor Ignition Coil with Igniter Injector Knock Sensor Engine Coolant Temperature Sensor Canister Filter Fuel Pump Crankshaft Position Sensor TWCs Canister Pump Module Vent Valve Leak Detection Pump Canister Pressure Sensor Heated Oxygen Sensor Bank 1 Sensor 2 Air Fuel Ratio Sensor Bank 1 Sensor 1 EG 29 3 Engine Control System Diagram f...

Page 29: ...Mass Air Flow Meter Built in Intake Air Temperature Sensor Accelerator Pedal Position Sensor DLC3 Fuel Pump Camshaft Timing Oil Control Valve Ignition Coil with Igniter Camshaft Position Sensor Engine Coolant Temperature Sensor Air Fuel Ratio Sensor Bank 1 Sensor 1 Injector Knock Sensor Crankshaft Position Sensor Throttle Body EG 30 4 Layout of Main Components ...

Page 30: ... Rotor Teeth Pickup Coil Type 36 2 1 This sensor detects the engine speed and performs the cylinder identification Camshaft Position Sensor Rotor Teeth Pickup Coil Type 3 1 This sensor performs the cylinder identification Engine Coolant Temperature Sensor Thermistor Type 1 This sensor detects the engine coolant temperature by means of an internal thermistor Intake Air Temperature Sensor Thermistor...

Page 31: ...characteristics Approximately 0 4V is constantly applied to the air fuel ratio sensor which outputs an amperage that varies in accordance with the oxygen concentration in the exhaust emission The ECM converts the changes in the output amperage into voltage in order to linearly detect the present air fuel ratio The output voltage of the heated oxygen sensor changes in accordance with the oxygen con...

Page 32: ...ater construction that are used The cup type sensor contains a sensor element that surrounds a heater The planer type sensor uses alumina which excels in heat conductivity and insulation to integrate a sensor element with a heater thus realizing the excellent warm up performance of the sensor Warm up Specification Sensor Type Planer Cup Type Warm up Time Approx 10 sec Approx 30 sec Mass Air Flow M...

Page 33: ...fers from the conventional contact type throttle position sensor because this non contact type sensor uses a Hall IC For details refer to the 2006 Yaris Repair Manual Pub No RM00R0U EG 34 Throttle Position Sensor The throttle position sensor is mounted on the throttle body to detect the opening angle of the throttle valve The throttle position sensor converts the magnetic flux density that changes...

Page 34: ...ls refer to the 2006 Yaris Repair Manual Pub No RM00R0U EG 35 Accelerator Pedal Position Sensor The non contact type accelerator pedal position sensor used a Hall IC The magnetic yoke that is mounted at the accelerator pedal arm rotates around the Hall IC in accordance with the amount of effort that is applied to the accelerator pedal The Hall IC converts the changes in the magnetic flux that occu...

Page 35: ...nd an accelerator pedal position sensor has been provided on the accelerator pedal In the conventional throttle body the throttle valve opening is determined invariably by the amount of the accelerator pedal effort In contrast the ETCS i uses the ECM to calculate the optimal throttle valve opening that is appropriate for the respective driving condition and uses a throttle control motor to control...

Page 36: ... details refer to Main Components of Engine Control System section on page EG 34 2 Throttle Control Motor A DC motor with excellent response and minimal power consumption is used for the throttle control motor The ECM performs the duty ratio control of the direction and the amperage of the current that flows to the throttle control motor in order to regulate the opening of the throttle valve Opera...

Page 37: ...rottle to an optimal throttle valve opening that is appropriate for the driving condition such as the amount of the accelerator pedal effort and the engine speed in order to realize excellent throttle control and comfort in all operating ranges Control Examples During Acceleration and Deceleration 3 Idle Air Control The ECM controls the throttle valve in order to constantly maintain an ideal idle ...

Page 38: ...ion Sensor The accelerator pedal position sensor is comprised of two main sub sensor circuits If a malfunction occurs in either one of the sensor circuits the ECM detects the abnormal signal voltage difference between these two sensor circuits and switches to the limp mode In the limp mode the remaining circuit is used to calculate the accelerator pedal depressed angle in order to operate the vehi...

Page 39: ...or circuits the ECM detects the abnormal signal voltage difference between these two sensor circuits cuts off the current to the throttle control motor and switches to the limp mode Then the force of the return spring causes the throttle valve to return and stay at the prescribed opening angle At this time the vehicle can be driven in the limp mode while the engine output is regulated through the ...

Page 40: ...ed to control the intake camshaft within a range of 40 of Crankshaft Angle to provide valve timing that is optimally suited to the engine condition This realizes proper torque in all the speed ranges as well as realizing excellent fuel economy and reducing exhaust emissions Using the engine speed signal vehicle speed signal and the signals from mass air flow meter throttle position sensor and wate...

Page 41: ...provement Eliminating overlap to prevent blow back to the intake side leads to the lean burning condition and stabilizes the idling speed at fast idle Eliminating overlap to reduce blow back to the intake side EG 42 Effectiveness of the VVT i System Operation State Objective Effect During Idling At Light Load Stabilized idling rpm Better fuel economy At medium Load Better fuel economy Improved emi...

Page 42: ...i controller vane circumferential direction to vary the intake valve timing continuously When the engine is stopped the intake camshaft will be in the most retarded state to ensure startability When hydraulic pressure is not applied to the VVT i controller immediately after the engine has been started the lock pin locks the movement of the VVT i controller to prevent a knocking noise 2 Camshaft Ti...

Page 43: ...the timing advance direction 2 Retard When the camshaft timing oil control valve is operated as illustrated below by the retard signals from the ECM the resultant oil pressure is applied to the timing retard side vane chamber to rotate the camshaft in the timing retard direction 3 Hold After reaching the target timing the valve timing is held by keeping the camshaft timing oil control valve in the...

Page 44: ...n Equipment EG 45 8 Fuel Pump Control A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed at the front side or rear side collision In this system the airbag deployment signal from the airbag assembly is detected by the ECM and it turns OFF the circuit opening relay After the fuel cut control has been activated turning the ignition switch from OFF to ON cancels the fuel...

Page 45: ...sion leak and outputs DTC Diagnostic Trouble Codes in the event of a malfunction An evaporative emission leak check consists of an application of a vacuum pressure to the system and monitoring the changes in the system pressure in order to detect a leakage This system consists of the purge VSV canister refueling valve canister pump module and ECM The ORVR Onboard Refueling Vapor Recovery function ...

Page 46: ...phere C i t Vent Valve Opens and closes the fresh air line in accordance with the signals from the ECM Canister Pump Module Leak Detection Pump Applies vacuum pressure to the evaporative emission system in accordance with the signals from the ECM Module Canister Pressure Sensor Detects the pressure in the evaporative emission system and sends the signals to the ECM Purge VSV Opens in accordance wi...

Page 47: ...e refueling valve to lift up allowing the fuel vapors to enter the canister The restrictor passage prevents the large amount of vacuum that is created during purge operation or system monitoring operation from entering the fuel tank and limits the flow of the vapor gas from the fuel tank to the canister If a large volume of vapor gas recirculates into the intake manifold it will affect the air fue...

Page 48: ...eak Detection Pump Pump Motor P Canister Pressure Sensor Filter Reference Orifice 0 5 mm 0 020 in Diameter To Canister EG 49 3 Canister Pump Module Canister Pump module consists of the vent valve leak detection pump and canister pressure sensor The vent valve switches the passages in accordance with the signals received from the ECM A DC type brush less motor is used for the pump motor A vane type...

Page 49: ...nister to ensure that purge flow is constantly maintained whenever purge vacuum is applied to the canister 2 ORVR On Board Refueling Vapor Recovery When the internal pressure of the fuel tank increases during refueling this pressure causes the diaphragm in the refueling valve to lift up allowing the fuel vapors to enter the canister Because the vent valve is always open even when the engine is sto...

Page 50: ...ment Leak detection pump creates negative pressure vacuum through 0 02 in orifice and the pressure is measured ECM determines this as 0 02 in leak pressure 60 sec 3 EVAP Leak Check Leak detection pump creates negative pressure vacuum in EVAP system and EVAP system pressure is measured If stabilized pressure is larger than 0 02 in leak pressure ECM determines EVAP system has a leakage If EVAP press...

Page 51: ...e Atmospheric Pressure Measurement EG 52 b Atmospheric Pressure Measurement 1 When the ignition switch is turned OFF the purge VSV and vent valve are turned OFF Therefore the atmospheric pressure is introduced into the canister 2 The ECM measures the atmospheric pressure through the signals provided by the canister pressure sensor 3 If the measurement value is out of standards the ECM actuates the...

Page 52: ... create a negative pressure 2 At this time the pressure will not decrease beyond a 0 02 in pressure due to the atmospheric pressure that enters through a 0 02 in diameter reference orifice measuring 0 5 mm 0 02 in 3 The ECM compares the logic value and this pressure and stores it as a 0 02 in leak pressure in its memory 4 If the measurement value is below the standard the ECM will determine that t...

Page 53: ...rns ON the vent valve in order to introduce a vacuum into the canister 2 When the pressure in the system stabilizes the ECM compares this pressure and the 0 02 in pressure in order to check for a leakage 3 If the detection value is below the 0 02 in pressure the ECM determines that there is no leakage 4 If the detection value is above the 0 02 in pressure and near atmospheric pressure the ECM dete...

Page 54: ...ressure Normal Purge VSV Monitor P0441 EG 55 e Purge VSV Monitor 1 After completing an EVAP leak check the ECM turns ON open the purge VSV with the leak detection pump actuated and introduces the atmospheric pressure from the intake manifold to the canister 2 If the pressure change at this time is within the normal range the ECM determines the condition to be normal 3 If the pressure is out of the...

Page 55: ...s the operation of the cooling fan based on the engine coolant temperature sensor signal Wiring Diagram Cooling Fan Operation Engine Coolant Temperature Low High Cooling Fan Operation OFF ON On the models with air conditioning the ECM controls the operation of the cooling fan in two speeds Low and Hi based on the engine coolant temperature sensor signal and the A C ECU signal The Low speed operati...

Page 56: ... START position this control continues to operate the starting until the engine starts without having to hold the ignition switch in the START position This prevents starting failures and the engine from being cranked after the engine has started When the ECM detects a start signal from the ignition switch this system monitors the engine speed NE signal and continues to operate the starter until i...

Page 57: ...lay After the starter operates and the engine speed becomes higher than approximately 500 rpm the ECM determines that the engine has started and stops the operation of the starter If the engine has any failure and does not work the starter operates as long as its maximum continuous operation time and stops automatically The maximum continuous operation time is approximately 2 seconds through 25 se...

Page 58: ...DTCs Diagnostic Trouble Codes have been made to correspond to the SAE controller codes Some of the DTCs have been further divided into smaller detection areas than in the past and new DTCs have been assigned to them For details refer to the 2006 Yaris Repair Manual Pub No RM00R0U 13 Fail Safe When a malfunction is detected at any of the sensors there is a possibility of an engine or other malfunct...

Page 59: ...EG 60 MEMO ...

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