Engine Engine Overall Intake & Exhaust System Fuel System Charging System Engine Control System

Engine Engine Overall Engine Specification -A Model 2UZ-FE (‘03 GX470) 2UZ-FE (‘03 LX470) No. of Cylinders and Arrangement 8-Cylinder, V type  Valve Mechanism 32-Valve DOHC Belt & Gear Drive Displacement 4664 cm3 (284.5 cu in.) Bore X Stroke 94.0 X 84.0 mm (3.70 X 3.31 in.) Compression Ration 9.6 : 1 Maximum Output (SAE-NET) [kW @ rpm (HP @ rpm)] 175@4800 (235@4800) Maximum Torque (SAE-NET) [N·m @ rpm (ft·lbf @ rpm)] 434@3400 (320@3400)

Engine Engine Overall Engine Specification -A The major difference from the 2UZ-FE of ‘03 LX470 The carbon filter is used at air cleaner The number of TWC Plastic made type fuel tank is used Quick type fuel cap is used A no-contact type accelerator pedal position sensor is used The construction of evaporative emission control system

Engine Intake & Exhaust System Carbon Filter Carbon filter adsorb HC in intake system to reduce evaporative emission Carbon Filter (Maintenance-free) Air Flow Air Cleaner

Engine Intake & Exhaust System TWC Three TWCs are used to meet LEV I

Reference Intake & Exhaust System TWC -A Cell Density: 62 cells / cm2 Wall Thickness : 0.115 mm Volume : 1307 cm3 Material : Ceramic Cell Density: 93 cells / cm2 Wall Thickness : 0.09 mm Volume : 1083 cm3 Material : Ceramic Noble Platinum Portion

Engine Fuel System Fuel Tank Multiplex layer plastic made type fuel tank is used to comply the LEV II regulations Front Cross Section Outside Multiplex layer -HDPE(High density polypropylene) resin fuel tank -Multi layer (6 layers) construction Inside

Engine Fuel System Fuel Tank Cap Quick-type fuel tank cap has been adopted to improve usability -Quick type fuel cap ensures 1/3 turns for open / close -Tether adoption

Engine Charging System Alternator Compact and lightweight SC (Segment Conductor) type alternator is used Segment Conductor Twisted Joined A Cross Section Diagram -Square shape conductor for area expanding for higher performance -Higher current flow makes higher performance Stator A Joined Segment Conductor System

Engine Engine Control System ETCS-i -A Engine Engine Control System ETCS-i Evaporative Emission Control System Cranking Hold Function Diagnosis

Engine Engine Control System ETCS-i -A Engine Engine Control System ETCS-i In the new 2UZ-FE engine, the link-less type ETCS-i is used ’03 GX470 ECM Accelerator Pedal Position Sensor Throttle Control Motor Throttle Position Sensor

Engine Engine Control System ETCS-i -A Engine Engine Control System ETCS-i A no-contact type throttle position sensor is used Reduction Gears Throttle Control Motor Throttle Valve Throttle Position Sensor Hall ICs Magnets

Reference Engine Control System ETCS-i -A Reference Engine Control System ETCS-i Two Hall ICs and two magnets are used for throttle position sensor Hall ICs Magnets Throttle Valve

Engine Engine Control System ETCS-i -A Engine Engine Control System ETCS-i Throttle position sensor converts into electric signals the magnetic flux density ECM Magnet VC 5 5 VTA2 VTA2 VTA1 Hall ICs VTA VC Output Voltage (V) Output Voltage (V) ECM E2 VTA2 VTA1 VTA VTA2 E2 Magnets Hall IC Full Close Full Close Full Open Full Open Throttle Valve Opening Angle Throttle Valve Opening Angle

Throttle Position Sensor -A Service Point Engine Control System ETCS-i Inspection of the throttle position sensor is discontinued from the contact type Contact type No-contact type (’03 GX470) Inspection Inspection Throttle Position Sensor VC  E2 : 1.25 – 2.35 k at 20C (68 F) Throttle Position Sensor None The throttle position sensor can not be inspected

Engine Engine Control System ETCS-i -A Engine Engine Control System ETCS-i A no-contact type accelerator pedal position sensor is used Magnets Hall ICs Accelerator Pedal Arm Hall IC uses and makes no contact type sensor for better durability

Accelerator Pedal Depressed Angle Engine Engine Control System ETCS-i Accelerator pedal position sensor converts into electric signals the magnetic flux density VPA ECM Magnets EPA 5 VPA2 VCPA Output Voltage (V) VPA2 VPA EPA2 Hall ICs Full Close Full Open VCP2 Accelerator Pedal Depressed Angle

Accelerator Pedal Position Sensor Service Point Engine Control System ETCS-i Inspection of the accelerator pedal position sensor is discontinued from the contact type Contact type No-contact type (’03 GX470) Inspection Inspection Accelerator Pedal Position Sensor VC  E2 : 1.64 – 3.28 k at 20C (68 F) Accelerator Pedal Position Sensor None No contact ,no inspection for electrical circuit The accelerator pedal position sensor can not be inspected

Engine Engine Control System Evaporative Emission Control System The construction is changed to comply with the LEV-II evaporative emission regulations To Intake Manifold Tank Pressure Valve Vapor Pressure Sensor Restrictor Passage Charcoal Canister Purge Valve Air Filter Canister Close Valve The construction is simpler than the conventional vacuum type

Reference Engine Control System Evaporative Emission Control System Conventional vacuum type Vapor Pressure Sensor Tank Pressure Valve ORVR Valve To Intake Manifold Charcoal Canister From Air Connector Pipe Canister Close Valve Pressure Switching Valve Air Drain Valve Air Inlet Valve Purge Valve

Engine Engine Control System Evaporative Emission Control System Location Purge Valve Service Port Tank Pressure Valve Charcoal Canister Air Filter Canister Close Valve Vapor Pressure Sensor

Engine Engine Control System Evaporative Emission Control System Charcoal canister assembly Canister Closed Valve Charcoal Canister (3.0 liters) To Fresh Air Line Tank Pressure Valve To Intake Manifold From Fuel Tank

*: It will affect the air-fuel ratio control of the engine Engine Control System Evaporative Emission Control System The vapor guide prevents the vapor gas without passing through the activated charcoal From Fuel Tank From Fuel Tank Vapor Guide To Intake Manifold To Intake Manifold Clean air Include vapor gas* Absorb vapor gas With vapor guide Without vapor guide *: It will affect the air-fuel ratio control of the engine

Engine Engine Control System Evaporative Emission Control System Tank pressure valve controls the flow rate of the vapor gas from fuel tank to charcoal canister Tank Pressure Valve Vapor Gas (From Fuel Tank) Restrictor Passage When refueling (Tank pressure is large) From Fuel Tank

Engine Engine Control System Evaporative Emission Control System The restrictor passage prevents the large amount of vacuum that is created during system monitoring from entering the fuel tank From Fuel Tank Vacuum Restrictor Passage Restrictor Passage If the large amount of vacuum enters the fuel tank during system monitoring, system monitoring is not performed normally

The air filter is maintenance-free Engine Engine Control System Evaporative Emission Control System The air filter prevents dust and debris in the fresh air from entering the system To Charcoal Canister To Fresh Air The air filter is maintenance-free

Service Point Engine Control System -A Service Point Engine Control System Evaporative Emission Control System If the air filter becomes clogged, the ECM illuminates the MIL and record the DTC P0446 DTC P0446 is detected (Canister Closed Valve close malfunction) Canister closed valve is OK The air filter is clogging

Engine Engine Control System Evaporative Emission Control System Stored fuel vapors are purged from the charcoal canister when the purge valve is opened by ECM To Intake Manifold ECM Stored fuel vapors Duty Atmosphere OPEN OPEN

Engine Engine Control System Evaporative Emission Control System When refueling, the fuel vapors enter to the charcoal canister and they are cleaned The internal pressure increases ECM OPEN Close OPEN The fuel vapors are Cleaned

Engine Engine Control System Evaporative Emission Control System When the initial conditions are met, the ECM introduces a vacuum into the system and monitors system to detect system malfunction Initial conditions are met P1’ 0 mmHg P1 Fuel Tank Pressure The ECM monitors the amount of pressure increase in the fuel tank Value B P2 Value A Purge Valve Open Close Open Canister Closed Valve Close

The ECM measures the amount of pressure increase (P1) in the fuel tank Engine Engine Control System Evaporative Emission Control System System monitoring (Step1) The ECM measures the amount of pressure increase (P1) in the fuel tank P1 Fuel Tank Pressure 0 mmHg P1 15 secs. Purge Valve Close Canister Closed Valve Close

Engine Engine Control System Evaporative Emission Control System System monitoring (Step2) The ECM opens the purge valve and introduces a vacuum into the fuel tank Fuel Tank Pressure Open Purge Valve Canister Closed Valve Close

The ECM measures the amount of pressure increase (P2)in the fuel tank Engine Engine Control System Evaporative Emission Control System System monitoring (Step3) The ECM measures the amount of pressure increase (P2)in the fuel tank Value B Fuel Tank Pressure P2 Below value A P2 Value B 5 secs. Value A Purge Valve Close Canister Closed Valve Close

Engine Engine Control System Evaporative Emission Control System System leak judgment P2 Measurement P2 > Reference Value* Presumes presence of system leak P2 < Reference Value* Judges absence of system leak *: Reference value is stored in the ECM Normal system control P1 is small Judges presence of system leak P1 is large Judges P1 again (P1’)

Judges presence of system leak P1’ is large Repeats judgment P1’ Measurement P1’ is small Judges presence of system leak P1’ is large Repeats judgment The MIL illuminates and ECM stores the following DTCs in its memory Level of Leak DTC Very small, small or medium leak P0442 and/or P0456 Large leak P0441, P0442 and P0446

Engine Engine Control System Evaporative Emission Control System VSV monitoring (Normal condition) Purging System monitoring System leak judgment Purge Valve Open Close Open Canister Closed Valve Close Fuel Tank Pressure

Engine Engine Control System Evaporative Emission Control System VSV monitoring (Purge valve open malfunction) Engine Starting When the ECM is measuring the P1 value, the pressure in the fuel tank drops rapidly Purge Valve Open Normal Condition Canister Closed Valve Fuel Tank Pressure Malfunction Judgment It remains in a constant, slight vacuum state DTC P0441 is memorized, The MIL illuminates

Engine Engine Control System Evaporative Emission Control System VSV monitoring (Purge valve close malfunction) No vacuum is introduced Purge Valve Close Canister Closed Valve Fuel Tank Pressure Malfunction Judgment The pressure does not change DTC P0441, P0442 and P0446 is memorized, The MIL illuminates

Engine Engine Control System Evaporative Emission Control System VSV monitoring (Canister closed valve open malfunction) It is not possible to completely introduce a vacuum Purge Valve Open Canister Closed Valve Fuel Tank Pressure Malfunction Judgment A slight vacuum is created DTC P0441, P0442 and P0446 is memorized, The MIL illuminates

Engine Engine Control System Evaporative Emission Control System VSV monitoring (Canister closed valve close malfunction) A large amount of vacuum is introduced Purge Valve Canister Closed Valve Close Fuel Tank Pressure Malfunction Judgment DTC P0446 is memorized, The MIL illuminates

Operates Automatically Engine Engine Control System Cranking Hold Function Once the ignition switch is turned to the START position, this control continues to operate starter until engine starts “Start” “ON” Ignition Switch Operates Automatically Starter Operate Stop Engine starts

Engine Engine Control System Cranking Hold Function System Diagram -A Audio & Illumination ACC ACC Cut Relay Ignition Switch Starter Relay马达继电器 Engine ECU (ECM) ST Park/Neutral Position Switch THW Engine Coolant Temp. Sensor水稳传感器 Starter马达 NE Crankshaft Position Sensor机油位置传感器

Engine Engine Control System Cranking Hold Function The ACC cut relay cuts off the ACC circuit while engine is cranking to prevent the accessory illumination from operating intermittently Audio & Illumination ACC ACC Cut Relay Ignition Switch Starter Relay Engine ECU (ECM) ST Park/Neutral Position Switch THW Engine Coolant Temp. Sensor Starter NE Crankshaft Position Sensor

Automatically Controlled Engine Engine Control System Cranking Hold Function (Operation) 0.2 sec. or more : With this system Ignition Switch Start : Without this system ON ACC Cut Relay Automatically Controlled Starter Relay Judgment NE Signal Time

Engine Coolant Temp. (C) Reference Confidential Engine Control System Cranking Hold Function Judgment of the engine starting Reference Value!! 900 Engine Coolant Temp. Judgment Level Above 0 C (32 F) Approx. 500 rpm Below 0 C (32 F) Approx. 500 - 900 rpm Judgment Level (rpm) 500 Engine Coolant Temp. (C)

Engine Reference Value!! Confidential Engine Control System Cranking Hold Function The maximum cranking time will be changed with engine coolant temp. Reference Value!! Max. Cranking Time (sec.) Engine Coolant Temp. (°C (°F)) Max. Cranking Time (sec.) 100 (212) Approx. 2 0 (32) Approx. 5 -30 (-22) Approx. 25 5 Engine Coolant Temp. (C) When engine coolant temp. is lower, the time limit is longer

Engine Engine Control System Cranking Hold Function If the engine is already running, the ECM will not energize to the starter relay Start Ignition Switch ON Starter Relay OFF 700 rpm Engine is already running NE Signal

Driver operates intentionally Engine Engine Control System Cranking Hold Function If the engine speed becomes 1200 rpm or more while cranking, the ECM turns off a starter relay to prevent starter overrun Start Ignition Switch Driver operates intentionally ON OFF Starter Relay 1200 rpm NE Signal Time

Driver operates intentionally Engine does not start (Problem) Engine Control System Cranking Hold Function When a starter is intentionally operated by the driver, the ECM turns off a starter relay after 30 sec. in order to prevent starter overheating Start Ignition Switch Driver operates intentionally ON 30 sec. OFF Starter Relay NE Signal Engine does not start (Problem) Time

Engine Engine Control System Diagnosis To comply with the OBD-II regulations, all the DTC have been made to correspond to SAE controlled codes. Some of the DTC have been further divided into smaller detection area than in the past, and new DTC have been assigned to them. Example New DTC Old DTC DTC Detection Item P0031 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 1) P0032 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 1) DTC Detection Item P0135 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)