Verso-s 1ND-TV gen3 Euro 5

No. of Cylinders and Arrangement Flow of Intake and Exhaust Gases Engine Overall 1ND-TV Engine Engine 1ND-TV No. of Cylinders and Arrangement 4-cylinder, In-line Valve Mechanism 8-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 [Nm @ rpm] 205 @ 1,800 to 2,800 Valve Timing Intake Open 4º BTDC Closed 36º ABDC Exhaust 44º BBDC 4º ATDC Oil Grade ACEA C2 Fuel Cetane Number 48 or higher Firing Order 1 –3 – 4 – 2 Emission Regulation EURO V 1ND-TV

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

Engine Overall Specifications Model Verso-s Urban Cruiser No. of Cylinders and Arrangement 4-Cylinder, In-line  Valve Mechanism 8-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 Intake Open 4º BTDC Close 36º ABDC Exhaust 44º BBDC 4º ATDC Firing Order 1 – 3 – 4 - 2 Emission Regulation EURO V Euro IV Engine Oil Viscosity / Grade 0W-30 or 5W-30 /ACEA C2

Engine Overall Main Features [1/2] Item Feature 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 Mechanism A 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 Exhaust System The Exhaust Manifold Converter Uses Oxidation Catalyst (5) The DPF Catalytic Converter is Used 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

Emission Control System Engine Overall Main Features [2/2] Item Feature 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 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 Emission Control System A DC Motor Type EGR Valve is Used A Water-cooled Type EGR Cooler with Bypass Switching Valve is Used 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 A Pilot Injection Control is Used A Oil Maintenance Management System is Used Brake Override System is Used

Engine Overall Engine Serial Number Engine Serial Number

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

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

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

Lubrication System 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 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 Filter Replaceable Element Type

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

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

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

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

Opening Pressure of Piston Oil Jet Lubrication System 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 To Engine Parts ON Engine Speed [rpm] Oil Pressure [kPa] Opening Pressure of Piston Oil Jet Open Sleeve 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

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 increases To Engine Parts OFF Engine Speed [rpm] Oil Pressure [kPa] Opening Pressure of Piston Oil Jet Close Sleeve 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 valve From Oil Pan

Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) New DTCs DTC 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 P0524 Engine Oil Pressure Too Low • Oil pressure switching valve assembly P06DA Engine Oil Pressure Control Circuit Open • Open or short in oil pressure switching valve assembly control circuit - P06DB Engine Oil Pressure Control Circuit Low P06DC Engine Oil Pressure Control Circuit High • Short in oil pressure switching valve assembly control circuit

DTC Detection Condition Lubrication System Oil Pump (Electrically Variable Oil Pressure Type) DTC Detection Condition DTC DTC 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. 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 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 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. NOTE: Perform this check when DTC P0524 is output.

Lubrication System Service Point Engine Oil Pressure Control Check

Oil Pressure Switching Valve Lubrication System Service Point Engine Oil Pressure Control Check Vehicle operation during this check Active Test Start Active Test Finish High Oil Pressure Low ON Oil Pressure Switching Valve 5 Sec. 5 Sec. 5 Sec. OFF During this check, the engine speed will increase (Approx. 2000 rpm) and the oil pressure switching valve will switch automatically. Engine Speed [rpm] 2,000 Idle Time

Lubrication System Service Point Engine Oil Pressure Control Check Reference oil pressure Item Specified 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.

Lubrication System Service Point Engine Oil Pressure Control Check (Not Using Tester) Standard oil pressure Measurement Results 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 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 HINT: When not using the intelligent tester, it is not possible to determine whether the system is stuck in high oil pressure control mode.

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 Type Capacity Toyota Super Long Life Coolant w/o Combustion Type Power Heater 4.9 liters w/ Combustion Type Power Heater 5.3 liters

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

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

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

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

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 Water-cooled Type EGR Cooler with Bypass Switching Valve DC Motor Type EGR Valve

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

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) 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 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 at around 60 km/h (36 mph) for approximately 20 minutes*. It can be also made to regenerate by normal driving at an engine speed of 2000 rpm or higher for approximately 20 minutes*. The DPF system warning light will extinguish when regeneration is complete. If the regeneration is not complete after driving for 45 minutes, the warning light will turn off once. (In this case, the warning light may turn on again.) If the above mentioned driving cannot be carried out, or if the light does not extinguish even after driving, have the vehicle inspected by any authorized Toyota dealer or repairer, or another duly qualified and equipped professional immediately. Malfunction indicator light If you continue driving while the DPF system warning light is flashing, the malfunction indicator light will illuminate. In this event, damage may be caused to the vehicle or an accident may occur. Have the vehicle inspected by any authorized Toyota dealer or repairer, or another duly qualified and equipped professional, immediately. NOTICE ■DPF warning light If you continuously drive for short distances, the DPF warning light may flash or illuminate. In this event, have the vehicle inspected by any authorized Toyota 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 is flashing ●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

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

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

Engine Control System Main Components Components Outline Quantity Atmospheric Temperature Sensor Thermistor Type 1 Air Flow Meter Hot-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 Sensor Accelerator Pedal Sensor Non-contact Type Throttle Position Sensor Injector Piezo Type (7-hole Type) 4 Turbo Pressure Sensor Semiconductor Silicon Chip Type Intake Air Temperature Sensor Fuel Pressure Sensor Semiconductor Strain Gauge Type Fuel Temperature Sensor Engine Oil Level Sensor ON/OFF Switch Type

Engine Control System System Control Table [1/2] System Outline 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.

Engine Control System System 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 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

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 Pilot Quantity Learning Value Reset DPF Deterioration Record Clear A/F Sensor Compensation Reset Vehicle Mileage Write

Engine Control System Service Point Initialization and Registration Function of utility items Utility Item Function Learning Values Save This 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 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.

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 performance Accelerator pedal is depressed Both pedals are depressed Restrain the engine output Engine Output Restraint Time System Start

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

Engine Control System Brake Override System Operation Start Condition No Accelerator pedal position is more than predetermined value Yes No Brake pedal is depressed (Stop Light Switch: OFF  ON) Yes No Vehicle is decelerating (Deceleration Judgment is ON)* Yes No Vehicle speed is more than predetermined value Yes Engine output by actual accelerator pedal position Engine Output Restraint If the accelerator pedal is depressed while the brake pedal depressing, this system does not operate. Vehicle deceleration is calculated from vehicle speed signal. Time Operation 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

Accelerator Pedal Position Engine Control System Brake Override System Deceleration Judgment The deceleration judgment is used in order to judge the deceleration intention of the customer surely Fully Depressed The 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 Position In 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

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