Toyota 4a-Fe Engine Reference

30

ENGINE – 4A-FE ENGINE

ENGINE 4A-FE ENGINE (STOICHIOMETRIC) JDESCRIPTION The intake and exhaust systems of the 4A-FE engine for the Europe model have been revised to improve engine performance. In addition, the engine control system has been revised to reduce the exhaust emissions. The 4A-FE engine for General Countries has improved its torque in the low- to mid-speed range by revising its intake manifold. "

For Europe A

145EG01

"

145EG02

For General Countries A

145EG03

145EG04

31

ENGINE – 4A-FE ENGINE

JENGINE SPECIFICATIONS AND PERFORMANCE CURVES 4A-FE Engine

New

Previous

No. of Cyls. & Arrangement

4-Cylinder, In-Line

z

Valve Mechanism

16-Valve, DOHC, Belt & Gear Drive

z

Pentroof Type

z

Cross-Flow

z

EFI

z

(cu. in.)

1587 (96.8)

z

mm (in.)

81.0 x 77.0 (3.19 x 3.03)

z

9.5 : 1

z

81 kW@6000 rpm

78 kW@6000 rpm*1 81 kW@6000 rpm*2

Item

Combustion Chamber Manifold Fuel System cm3

Displacement Bore x Stroke Compression Ratio Max. Output

[EEC]

Max. Torque

[EEC] Intake

Valve Timing Exhaust Fuel Octane Number

145 N.m@4800 rpm

137 X 5400 142 N.m@4800 rpm*2 N.m@4800

Open

6_BTDC

z

Close

46_ABDC

z

Open

38_BBDC

z

Close

6_ATDC

z

95*1, 90 or 95*2

z

API SH EC-II, SJ EC or ILSAC

z

(RON)

Oil Grade

EG

rpm*1

*1: Models for Europe *2: Models for General Countries For Europe A

"

kW 90 N.m 160

80

140

Torque

70 60

120

50

100 40

1000 2000 3000 4000 5000 6000 7000 Engine Speed (rpm) 145EG09

80 70

140 60 120 50

100

40

30

30

20

20

10

10

0

0 1000 2000 3000 4000 5000 6000 7000 Engine Speed (rpm)

Output

N.m 160 Torque

For General Countries A

kW 90

: New : Previous

Output

"

145EG10

32

ENGINE – 4A-FE ENGINE

JMAJOR DIFFERENCES The following changes have been made to the 4A-FE Engine. Features

Europe

General Countries

An aluminum radiator core is used for weight reduction.

f

f

The ports of the intake manifold have been extended to improve torque in the low-to mid-speed range.

f

f

A dual exhaust manifold has been adopted to improve engine performance.

f

–

D A ball joint has been adopted in the front exhaust pipe to reduce noise and vibration. D The internal construction of the main muffler has been optimized to improve its quietness and reduce the exhaust pressure. D The support of the main muffler has been changed from the 3-point to 2-point support to reduce the noise and vibration that are transmitted to the body.

f

f

Fuel System

A fuel returnless system has been adopted to reduce evaporative emissions.

f

–

Engine Control System

D The fuel injection system is changed from a 2-group injection type to sequential multiport fuel injection type. D The power steering idle-up control has been changed from the system using an air control valve to the one using a pressure switch and an ISC valve. D The radiator cooling fan is now controlled by the engine ECU. D M-OBD (Multiplex On-Board Diagnosis) system is adopted.

f

–

Item Cooling System

Intake and Exhaust System

ENGINE – 4A-FE ENGINE

33

JINTAKE AND EXHAUST SYSTEM 1. Intake Manifold D The intake manifold has been integrated with the intake air chamber for weight reduction. D The length of the intake port has been optimized to improve the torque in the low-to midrange engine speed.

145EG13

2. Exhaust Manifold A dual exhaust manifold made of stainless steel has been adopted to improve engine performance.

145EG14

EG

34

ENGINE – 4A-FE ENGINE

3. Exhaust Pipe D A ball joint has been adopted in the front exhaust pipe to reduce noise and vibration transmitted to the exhaust pipe. D The outlet pipe in the main muffler has been extended and various components have been optimally located to improve quietness and reduce the exhaust pressure. Front Exhaust Pipe

: Extended Portion Outlet Pipe

Gasket

Spring

Bolt

Exhaust Gas 145EG15

145EG16

Main Muffler

Ball Joint

JFUEL SYSTEM 1. Fuel Returnless System The new Avensis has adopted a fuel returnless system to reduce evaporative emissions. With the pressure regulator housed inside the fuel tank, this system eliminates the return of fuel from the engine area.

Injector

Injector

Pressure Regulator Pulsation Dumper

Fuel Filter

Delivery Pipe Pressure Regulator Fuel Tank

Fuel Pump

Fuel Filter

New

Fuel Filter

Delivery Pipe

Fuel Tank

Fuel Return Pipe

Fuel Pump

Previous 145EG33

35

ENGINE – 4A-FE ENGINE

JENGINE CONTROL SYSTEM (BOSCH TYPE) 1. General The (Bosch Type) engine control system of the 4A-FE engine for the Europe model has adopted the Sequential Multiport fuel injection system and the M-OBD (Multiplex On-Board Diagnosis) system. The engine control system on the model for General Countries is basically the same as that of the previous model. The engine control system (Bosch Type) of the new 4A-FE engine and previous 4A-FE engine are compered below. Outline

New

Previous

A D-type EFI system is used, which indirectly detects intake air volume by manifold pressure sensor signal.

f

f

The fuel injection system is a sequential multiport fuel injection system.

f

–

The fuel injection system is a 2-group type, each of which injects 2 cylinders simultaneously.

–

f

Ignition timing is determined by the engine ECU based on signals from various sensors.

f

f

It retards ignition timing to suppress knocking when it occurs.

f

f

ISC (Idle Speed Control)

A rotary solenoid type ISC system is used to control the fast idle and idle speeds.

f

f

Fuel Pump Control

Fuel pump operation is controlled by signals from the engine ECU based on the engine speed signal (NE).

f

f

Engine Immobiliser

Prohibits fuel delivery and ignition if an attempt is made to start the engine with an invalid ignition key.

f

f

Air Conditioner Cut-Off Control

By controlling the air conditioner compressor in accordance with the throttle valve opening angle and the vehicle speed, driveability is maintained.

f

f

Cooling Fan Control

Radiator cooling fan operation is controlled by signals from engine ECU based on the water temperature sensor signal (THW).

f

–

When the engine ECU detects a malfunction, the engine ECU diagnoses and memorizes the failed section.

f

f

A newly developed diagnostic system which utilizes a high speed bi-directional communication line to provide extended diagnostic capabilities and features.

f

–

When the engine ECU detects a malfunction, the engine ECU stops or controls the engine according to the data already stored in memory.

f

f

System

EFI Electronic Fuel Injection

ESA Electronic Spark Advance

Diagnosis

Fail-Safe

EG

36

ENGINE – 4A-FE ENGINE

2. Construction The configuration of the engine control system in the 4A-FE engine of the new AVENSIS is as shown in the differ from the 4A-FE engine of the previous model. following chart. Shaded portions SENSORS

ACTUATORS

MANIFOLD PRESSURE SENSOR

PIM

EFI #10

CRANKSHAFT POSITION SENSOR D Engine Speed Signal D Crankshaft Angle Signal

#20 NE

#30 #40

HALL SENSOR

G

D Crankshaft Angle Signal

NO.2 INJECTOR NO.3 INJECTOR NO.4 INJECTOR

ESA IGT

THW

WATER TEMP. SENSOR

NO.1 INJECTOR

IGNITION COIL DISTRIBUTOR

THA

INTAKE AIR TEMP. SENSOR

SPARK PLUGS

THROTTLE POSITION SENSOR

VTA

D Throttle Position Signal IGNITION SWITCH

IGSW

D Ignition Signal

ISC Engine ECU

RSC RSO

FUEL PUMP CONTROL FC

COMBINATION METER

CONTROL VALVE

CIRCUIT OPENING RELAY

SPD

D Vehicle Speed Signal

AIR CONDITIONING CUT-OFF CONTROL

OX1

HEATED OXYGEN SENSOR

ACT KNK

KNOCK SENSOR

COMBINATION METER

IMI IMMOBILISER ECU IMO

AIR CONDITIONING AMPLIFIER

THWO

ENGINE COOLANT TEMP. GAUGE

PSW

POWER STEERING OIL PRESSURE SWITCH

COOLING FAN CONTROL AIR CONDITIONING AMPLIFIER DATA LINK CONNECTOR 3

A/C

FAN

SIL

W

TC +B

EFI MAIN RELAY

BATT BATTERY

COOLING FAN RELAY

CHECK ENGINE LAMP

37

ENGINE – 4A-FE ENGINE

3. Engine Control System Diagram

Vehicle Speed Sensor

Ignition Switch

Circuit Opening Relay

DLC3 Check Engine Lamp

Air Conditioning Amplifier

Fuel Pump Charcoal Canister Battery

EG Engine ECU

Starter Distributor Ignition Coil BVSV

Intake Air Temp. Sensor

Manifold Pressure Sensor Injector ISC Valve

Knock Sensor TWC

Water Temp. Sensor

Throttle Position Sensor

Heated Oxygen Sensor

Crankshaft Position Sensor 145EG17

Knock Sensor

Crankshaft Positon Senosr

Distributor (Hall Sensor)

Power Steering Oil Pressure Switch

Manifold Pressure Senosr

Engine ECU

Water Temp. Sensor

Intake Air Temp. Senosr

ISC Valve

145EG27

Ignition Coil

DLC3

Combination Meter

Heated Oxygen Sensor

Throttle Position Sensor

38 ENGINE – 4A-FE ENGINE

4. Layout of Components

39

ENGINE – 4A-FE ENGINE

5. Main Components of Engine Control System General The following table compares the main components of the 4A-FE engine in the new and previous model. Model

New

Previous

Semiconductor Type

z

Linear Type

z

Pick-Up Coil Type, 1

z

Hall Element Type

z

Knock Sensor

Built-In Piezoelectric Element Type, 1

z

Oxygen Sensor

With Heater Type

z

2-Hole Type

z

Rotary Solenoid Type

z

Component Manifold Pressure Sensor Throttle Position Sensor Crankshaft Position Sensor Distributor

Hall Sensor

Injector ISC Valve

6. EFI (Electronic Fuel Injection System) The injection pattern has been changed from the previous 2-group injection type to the Sequential Multiport fuel injection type to improve the precision of the air-fuel ratio feedback control.

7. ISC (Idle Speed Control) The power steering idle-up control has been changed from the system using an air control valve to the one using a pressure switch and an ISC valve.

8. Cooling Fan Control In the previous model, the operation of the cooling fan used to be controlled by the water temperature switch provided at the water inlet of the engine. In the new model, the cooling fan is controlled by the engine ECU based on the signal (THW) that is output by the water temperature sensor.

9. Engine Coolant Temperature Signal Output In place of the temperature sender gauge used on the previous model, the engine ECU sends the engine coolant temperature signal to the engine coolant temperature gauge in the combination meter.

EG

40

ENGINE – 4A-FE ENGINE

10. Diagnosis System The M-OBD (Multiplex On-Board Diagnostic) system that has been adopted in the 4A-FE engine is the system that has been improved upon the previous diagnostic system in order to perform troubleshooting in a more efficient and accurate manner. The functions of the M-OBD system can be fully utilized through the use of a hand-held tester. The following table compares the M-OBD system and previous diagnostic system. System

M-OBD

Item

Previous Diagnostic

The DLC3 (Data Link Connector 3) The check connector is provided. has been newly provided. In addition, the check connector terminals TE1, TE2, and IG have been discontinued. "

DLC3 A

"

Check Connector A

E1

TAC

TC

TE2

IG

TE1 Check Connector and Data Link Connector SIL

CG 140EG39 140EG127

VF1

CG: Chassis Ground SIL: Provides communication between the engine ECU and the hand-held tester. TAC: Outputs the engine speed signal. TC: Provides the same function as the previous TE1 terminal. Diagnostic Trouble Code Check Method

Output Engine ECU Date

After connecting terminals TC and CG of the DLC3, displays the code on CHECK Engine Lamp in the combination meter.

After connecting terminals TE1 and E1 of the check connector, displays the code on CHECK Engine Lamp in the combination meter.

The engine ECU’s control data can be The engine ECU’s control data can be output by connecting the hand-held output by connecting the hand-held tester to the DLC3. tester to the check connector. Output Date Speed: 9.6 kbps

Output Date Speed: 125 bps

41

ENGINE – 4A-FE ENGINE

Furthermore, on the M-OBD system, the functions listed below can be utilized by connecting the hand-held tester to the DLC3. Function

Details The system can output 5-digit diagnostic trouble codes to the tester, which are more detailed than the previous 2-digit diagnostic trouble codes, thus making it easier to identify the location of the problem.

Diagnostic Trouble Code

Example:

Freeze-Frame Data

The system can output freeze-frame data to the tester. This data (which depicts the condition of the engine control system and the vehicle) is stored in the engine ECU at the very moment when the engine ECU has detected its last data of malfunction.

Active Test

Through the use of the tester, the actuators (VSV, fuel pump, ISC valve etc.) can be activated to a desired state.

Trouble Code Clear

Through the use of the tester, trouble codes stored in the engine ECU can be cleared.

Code 28 (Oxygen Sensor)

P0130 (Oxygen Sensor) P0135 (Oxygen Sensor Heater)

D For details of the diagnostic trouble codes, active test, etc. described above, refer to the 4A-F, -FE/7A-FE, Engine Repair Manual Supplement (Pub. No. RM611E). D For details of the hand-held tester, refer to the Hand-Held Tester Operator’s Manual.

EG

42

ENGINE – 4A-FE AND 7A-FE ENGINES

4A-FE AND 7A-FE ENGINES (LEAN-BURN) JDESCRIPTION The 4A-FE and 7A-FE engines realized improvement in torque in the low- to mid-speed range by changing the intake manifold and improvement in fuel economy by adopting resin-coated pistons. "

4A-FE Engine A

145EG05

"

145EG06

7A-FE Engine A

145EG07

145EG08

43

ENGINE – 4A-FE AND 7A-FE ENGINES

JENGINE SPECIFICATIONS AND PERFORMANCE CURVE (4A-FE ENGINE) 4A-FE Engine

New

Previous

No. of Cyls. & Arrangement

4-Cylinder, In-Line

z

Valve Mechanism

16-Valve, DOHC, Belt & Gear Drive

z

Pentroof Type

z

Cross-Flow

z

EFI

z

(cu. in.)

1587 (96.8)

z

mm (in.)

81.0 x 77.0 (3.19 x 3.03)

z

9.5 : 1

z

Item

Combustion Chamber Manifold Fuel System cm3

Displacement Bore x Stroke Compression Ratio Max. Output

[EEC]

74 kW@5800 rpm

73 kW@5800 rpm

Max. Torque

[EEC]

136 N.m@4400 rpm

130 N.m@4800 rpm

Open

6_BTDC

z

Close

38_ABDC

z

Open

42_BBDC

z

Close

2_ATDC

z

95

z

API SH EC-II, SJ EC or ILSAC

z

Valve Timing Exhaust Fuel Octane Number

(RON)

Oil Grade

Torque

N.m 160

: New : Previous

kW 90 80 70

140

60

120

50

100

Output

Intake

40 30 20 10 0 1000 2000 3000 4000 5000 6000 7000

Engine Speed (rpm) 145EG11

EG

44

ENGINE – 4A-FE AND 7A-FE ENGINES

JENGINE SPECIFICATIONS AND PERFORMANCE CURVE (7A-FE ENGINE) 7A-FE Engine

New

Previous

No. of Cyls. & Arrangement

4-Cylinder, In-Line

z

Valve Mechanism

16-Valve, DOHC, Belt & Gear Drive

z

Pentroof Type

z

Cross-Flow

z

EFI

z

(cu. in.)

1762 (107.5)

z

mm (in.)

81.0 x 85.5 (3.19 x 3.37)

z

9.5 : 1

z

Item

Combustion Chamber Manifold Fuel System cm3

Displacement Bore x Stroke Compression Ratio Max. Output

[EEC]

81 kW@5600 rpm

79 kW@5600 rpm

Max. Torque

[EEC]

155 N.m@2800 rpm

150 N.m@2800 rpm

Open

2_BTDC

z

Close

42_ABDC

z

Open

38_BBDC

z

Close

6_ATDC

z

95

z

API SH EC-II, SJ EC or ILSAC

z

Valve Timing Exhaust Fuel Octane Number

(RON)

Oil Grade

Torque

N.m 160

: New : Previous

kW 90 80 70

140

60

120

50

100

Output

Intake

40 30 20 10 0 1000 2000 3000 4000 5000 6000 7000

Engine Speed (rpm) 145EG12

ENGINE – 4A-FE AND 7A-FE ENGINES

45

JMAJOR DIFFERENCES The following changes have been made to the 4A-FE and 7A-FE Engines. Item

Features

Engine Proper

D The cylinder head intake port has been changed in shape to improve engine performance and fuel economy. D The pistons have been coated with resin to reduce friction loss and improve fuel economy.

Valve Mechanism

The spring tension of the valve springs are reduced to reduce friction loss.

Cooling System

An aluminum radiator core is used for weight reduction.

Intake and Exhaust System

D The ports of the intake manifold have been extended to improve torque in the low- to mid-speed range. D A ball joint has been adopted in the front exhaust pipe to reduce noise and vibration. For details, see page 34. D The internal construction of the main muffler has been optimized to improve its quietness and reduce the exhaust pressure. For details, see page 34. D The support of the main muffler has been changed from the 3-point to 2-point support to reduce the noise and vibration that are transmitted to the body.

Fuel System

D 4-hole type fuel injectors have been adopted to improve the atomization of fuel. D A fuel returnless system has been adopted to reduce evaporative emissions. For details, see page 34.

Ignition System

D The DIS (Direct Ignition System) is used to enhance the reliability of the ignition system. D Iridium-tipped spark plugs have been adopted to improve ignition.

Engine Control System

D The ESA system of the 4A-FE engine has adopted a knocking correction function.* D 1 Coil type ISC valve has been adopted. D The power steering idle-up control has been changed from the system using an air control valve to the one using a pressure switch and an ISC valve. D The radiator cooling fan is now controlled by the engine ECU. D M-OBD (Multiplex On-Board Diagnosis) system is adopted. For detail, see page 40.

*: This function had already been adopted on the 7A-FE engine.

EG

46

ENGINE – 4A-FE AND 7A-FE ENGINES

JENGINE PROPER 1. Cylinder Head The cylinder head intake port (helical, straight) has been improved to improve engine performance and fuel economy. D The shape of the valve stem guide area of the helical port has been changed to improve the swirl ratio without reducing the intake air volume to stabilize the lean-burn performance. D The straight port diameter has been increased and the inside of the port has been made smoother to improve the volumetric efficiency during high-load conditions. D The area of the port communication passage has been reduced to optimize the fuel distribution to the helical and straight ports.

Valve Stem Guide Area

Increased

Helical Port

Straight Port 145EG21

145EG20

2. Piston The piston skirt has been coated with resin to reduce friction loss.

Resin Coting

145EG22

47

ENGINE – 4A-FE AND 7A-FE ENGINES

JINTAKE AND EXHAUST SYSTEM 1. Intake Manifold D The intake manifold has been integrated with the intake air chamber for weight reduction. D The length of the intake port has been optimized to improve the torque in the low- to midrange engine speed. D The intake air control valve and actuators have been integrated with the intake manifold.

Actuator

Intake Air Control Valve

EG 145EG23

JFUEL SYSTEM 1. Injector A 4-hole type fuel injector has been adopted to improve the atomization of fuel.

141EG12

48

ENGINE – 4A-FE AND 7A-FE ENGINES

JIGNITION SYSTEM 1. General A DIS (Direct Ignition System) has been adopted in the new 4A-FE and 7A-FE engines. The DIS improves the ignition timing accuracy, reduces high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS in new 4A-FE and 7A-FE engines are a 2-cylinder simultaneous ignition system which ignites 2-cylinders simultaneously with one ignition coil. From Battery IGT1 Camshaft Position Sensor

G

Igniter

No.1 Cylinder

IGF No.4 Cylinder Ignition Coil

Crankshaft NE Position Sensor

Engine ECU

From Battery IGT2

Igniter

No.2 Cylinder

Various Sensors

No.3 Cylinder TAC

Ignition Coil

To Tachometer

140EG37

2. Ignition Coil Construction Construction the DIS system of the 4A-FE and 7A-FE engines consists of 2 sets of ignition coils integrated with igniter and with the high-tension cords attached directly onto the ignition coil. Front

To High-Tension Cord

High-Tension Cords Secondary Coil

Igniter

Plug Caps Ignition Coils (with Ignitor)

Core

Primary Coil

Connector

Ignition Coil Cross Section 145EG24

145EG25

49

ENGINE – 4A-FE AND 7A-FE ENGINES Operation

Prompted by the IGT signal received from the engine ECU, the power transistors in the igniter cuts off the current to the primary coil in the ignition coil. Accordingly, the high voltage generated in the secondary coil is supplied simultaneously to the two spark plugs via the high-tension cords that are connected to the both ends of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe function to the engine ECU.

Engine ECU

From Battery Ignition Coil Igniter

IGT Spark Plugs IGF

EG

141EG06

3. Spark Plugs Iridium-tipped spark plugs have been adopted. Their center electrode is made of iridium, which excels in wear resistance. As a result, the center electrode is made with a smaller diameter and improved the ignition performance. "

0.7 mm

Iridium Tip Platinum Tip 151EG39

Recommended Spark Plugs A DENSO

SK20R-P13

Plug Gap

1.2 – 1.3 mm (0.047 – 0.051 in.)

50

ENGINE – 4A-FE AND 7A-FE ENGINES

JENGINE CONTROL SYSTEM 1. General In addition to newly adopting the knocking correction function in the ESA system of the 4A-FE engine, the engine control system for all models has adopted a cooling fan control system and M-OBD (Multiplex OnBoard Diagnosis) system. The engine control system of the new engines and previous engines are compered below. System EFI Electronic Fuel Injection

ESA Electronic Spark Advance

ISC Idle Speed Control Intake Air Control Fuel Pump Control Lean Mixture Sensor Heater Control Air Conditioning Cut-Off Control Cooling Fan Control Engine Immobiliser

Diagnosis

Fail-Safe Econodrive Monitor Control *: 7A-FE Engine Only

Outline A D-type EFI system is used, which indirectly detects intake air volume by the manifold pressure sensor signal. The fuel injection system is a sequential multiport fuel injection system. Ignition timing is determined by the engine ECU based on signals from various sensors. It retards ignition timing to suppress knocking if knocking occurs. In vehicles equipped with automatic transaxle, torque control compensation during gear shifting is used to minimize the shift shock.

New

Previous

f

f

f

f

f

f

f

f

f*

*f*

A rotary solenoid type ISC system is used, which controls the fast idle and idle speeds.

f

f

f

f

f

f

f

f

f

f

f

–

f

f

f

f

f

–

f

f

f

f

When the engine is under a light load and engine speed is below predetermined level fuel economy is improved by closing the intake air control valve. Fuel pump operation is controlled by signals from the engine ECU based on the engine speed signal (NE). Maintains the temperature of the lean mixture sensor at an appropriate level to increase accuracy of detection of the oxygen concentration in the exhaust gas. By turning the air conditioning compressor ON or OFF in accordance with the engine condition, drivability is maintained. Radiator cooling fan operation is controlled by signals from engine ECU based on the water temperature sensor signal (THW). Prohibits fuel delivery and ignition if an attempt is made to start the engine with an invalid ignition key. When the engine ECU detects a malfunction, the engine ECU diagnoses and memorizes the failed section. A newly developed diagnostic system which utilizes a high speed bi-directional communication line to provide extended diagnostic capabilities and features. When the engine ECU detects a malfunction, the engine ECU stops or controls the engine according to the data already stored in memory. Turns ON the indicator to inform the driver that the engine is operating at the lean-burn air-fuel ratio.

51

ENGINE – 4A-FE AND 7A-FE ENGINES

2. Construction The configuration of the engine control system in the new 4A-FE and 7A-FE engines is as shown in the foldiffer from the previous 4A-FE and 7A-FE engines. lowing chart. Shaded portions SENSORS

ACTUATORS

MANIFOLD PRESSURE SENSOR

PIM

EFI #10

CRANKSHAFT POSITION SENSOR D Engine Speed Signal D Crankshaft Angle Signal

#20

NE

#30 #40

CAMSHAFT POSITION SENSOR

NO.1 INJECTOR NO.2 INJECTOR NO.3 INJECTOR NO.4 INJECTOR

G

D Crankshaft Angle Signal

ESA IGT1,IGT2

IGNITER

THW

WATER TEMP. SENSOR

IGF

INTAKE AIR TEMP. SENSOR THROTTLE POSITION SENSOR

THA SPARK PLUGS VTA

ISC

D Throttle Position Signal

RSD

IGNITION SWITCH

IGNITION COIL

CONTROL VALVE

STA

D Starting Signal

FUEL PUMP CONTROL FC

COMBINATION METER

CIRCUIT OPENING RELAY

SPD

D Vehicle Speed Signal LS

LEAN MIXTURE SENSOR

Engine ECU

LEAN MIXTURE SENSOR HEATER CONTROL HT

KNK1

KNOCK SENSOR NEUTRAL START SWITCH* D Neutral Start Signal D Shift Lever Position Signal

INTAKE AIR CONTROL NSW R, 2, L

SCV

PSW

POWER STEERING OIL PRESSURE SWITCH

ACT

THWO ELS2

FRONT & REAR WINDOW DEFOGGER

ELS3

BLOWER SWITCH AIR CONDITIONING AMPLIFIER

DATA LINK CONNECTOR 3

ENGINE COOLANT TEMP. GAUGE COOLING FAN CONTROL

FAN

COOLING FAN RELAY

A/C IMI

IMMOBILISER ECU

AIR CONDITIONING AMPLIFIER COMBINATION METER

ELS

TAILLIGHT RELAY

VSV AIR CONDITIONING CUT-OFF CONTROL

STP

STOP LIGHT SWITCH*

LEAN MIXTURE SENSOR HEATER

IMO SIL TC

+B EFI MAIN RELAY

*: Applicable only to the automatic transaxle model.

ECONODRIVE MONITOR CONTROL ED W BATT BATTERY

ECONODRIVE MONITOR CHECK ENGINE LAMP

EG

52

ENGINE – 4A-FE AND 7A-FE ENGINES

3. Engine Control System Diagram Ignition Switch

Circuit Opening Relay

Vehicle Speed Sensor

DLC3 Check Engine Lamp

Fuel Pump

Air Conditioning Amplifier

Charcoal Canister Battery

Electric Load Switch

Engine ECU

Starter

Camshaft Position Sensor Intake Air Temp. Sensor

Ignition Coil x 2 BVSV (with Igniter) Manifold Pressure Sensor

ISC Valve

Lean Mixture Sensor

*1

Actuator

Throttle Position Senosr

*2 TWC

*3 Vacuum Tank

Crankshaft Position Sensor

*1: Knock Sensor *2: Water Temp. Sensor *3: VSV (for Intake Air Control)

145EG26

Crankshaft Position Sensor

Knock Sensor

Actuator (for Intake Air Control)

Lean Mixture Sensor

Power Steering Oil Pressure Switch

VSV (for Intake Air Control)

Engine ECU

Neutral Start Swithc

Manifold Pressure Sensor

Ignition Coil (with Igniter)

Intake Air Temp. Sensor

ISC Valve

Camshaft Position Sensor

145EG28

Throttle Position Sensor

DLC3

Combination Meter

Ignition Coil (with Igniter)

Water Temp. Sensor

ENGINE – 4A-FE AND 7A-FE ENGINES 53

4. Layout of Components

EG

54

ENGINE – 4A-FE AND 7A-FE ENGINES

5. Main Components of Engine Control System General The following table compares the main components of the 4A-FE and 7A-FE engines in the new and previous model. Model

New

Previous

Semiconductor Type

z

Linear Type

z

Crankshaft Position Sensor

Pick-Up Coil Type, 1

–

Camshaft Position Sensor

Pick-Up Coil Type, 1

–

Crankshaft Position Sensor

–

2 Pick-Up Coils in Series

Camshaft Position Sensor

–

Pick-Up Coil Type, 1

Built-In Piezoelectric Element Type, 1

Built-In Piezoelectric Element Type, 1*

With Heater Type

z

4-Hole Type

2-Hole Type

Rotary Solenoid Type (1-Coil Type)

Rotary Solenoid Type (2-Coil Type)

Component Manifold Pressure Sensor Throttle Position Sensor

Distributor

Knock Sensor Lean Mixture Sensor Injector ISC Valve *: 7A-FE Engine Only Camshaft Position Sensors

The camshaft position sensor consists of a magnet, coil and iron core, and it is mounted onto the right side of the cylinder head. Each time when the camshaft rotates, the distance between the camshaft position sensor and the pin installed on the camshaft is varied. This causes the magnetic flux passing through the coil in the camshaft sensor to increase and decrease and to generate an electromotive force. Since the voltage generated when the pin on the camshaft approaches the pickup coil is the opposite of when it departs, an alternating electrical current is produced. Camshaft Pin Magnet Coil

Iron Core Front

Camshaft Position Sensor 145EG34

Camshaft Position Sensor Cross Section 145EG35

55

ENGINE – 4A-FE AND 7A-FE ENGINES Crankshaft Position Sensor

The crankshaft position sensor also consists of a magnet, coil and iron core, and it is mounted on the oil pump body as illustrated below. The timing rotor is integrated with the crankshaft pulley. The rotor’s teeth are spaced 10_ apart according to crankshaft angle, but since there are 2 teeth missing, as illustrated below, there is a total of 34 teeth. Accordingly, the engine ECU can detect the crankshaft angle in addition to the crankshaft speed.

Crankshaft Position Sensor Coil

Magnet

EG

Iron Core Crankshaft Position Sensor Cross Section

Oil Pump Body

Timing Rotor 145EG36

145EG37

ISC Valve As on the previous model, a rotary solenoid type ISC valve is used to control the idle speed. However, instead of the 2 coils used on the previous model, the new model uses 1 coil to simplify its system.

Engine ECU

Engine ECU

ISC Valve

ISC Valve

RSD Driver

New

RSO RSC

Previous 141EG30

56

ENGINE – 4A-FE AND 7A-FE ENGINES

7. ISC (Idle Speed Control) The power steering idle-up control has been changed from the system using an air control valve to the one using a pressure switch and an ISC valve.

8. Cooling Fan Control In the previous model, the operation of the cooling fan used to be controlled by the water temperature switch provided at the water inlet of the engine. In the new model, the cooling fan is controlled by the engine ECU based on the signal (THW) that is output by the water temperature sensor.

9. Engine Coolant Temperature Signal Output In place of the temperature sender gauge used on the previous model, the engine ECU sends the engine coolant temperature signal to the engine coolant temperature gauge in the combination meter.

57

ENGINE – 3S-FE ENGINE

3S-FE ENGINE JDESCRIPTION The 3S-FE engine has improved its torque in the low- to mid-speed range by changing the intake manifold and has adopted the DIS (Direct Ignition System) for its ignition system.

JENGINE SPECIFICATIONS AND PERFORMANCE CURVES Engine

New

Previous

No. of Cyls. & Arrangement

4-Cylinder, In-Line

z

Valve Mechanism

4-Valve DOHC, Belt & Gear Drive

z

Pentroof Type

z

Cross-Flow

z

EFI

z

1998 (121.9)

z

86.0 x 86.0 (3.39 x 3.39)

z

9.8 : 1*1, 9.5 : 1*2

z

Europe

94 kW@5400 rpm

93 kW@5600 rpm

General Countries

91 kW@5400 rpm

95 kW@5600 rpm

Europe

178 N.m@4400 rpm

178 N.m@4400 X 4800 rpm

General Countries

178 N.m@4400 rpm

182 N.m@4400 rpm

Open

3_BTDC

z

Close

43_ABDC

z

Open

45_BBDC

z

Close

3_ATDC

z

Item

Combustion Chamber Manifold Fuel System Displacement

cm3 (cu. in.)

Bore x Stroke

mm (in.)

Compression Ratio Max. Output Max [EEC] Max. Torque Max [EEC] Intake Valve Timing Exhaust Fuel Octane Number Oil Grade *1: For Europe Model *2: For General Countries Model

RON

95*1,

90 or

95*2

API SH EC-II, SJ EC ILSAC

z z

EG

58

ENGINE – 3S-FE ENGINE "

For Europe A kW 100 90 80

170

70

160

60

150

50

140

Output

Torque

N.m 180

40 30 20 10 0 1000 2000 3000 4000 5000 6000 7000

Engine Speed (rpm)

For General Countries A

kW 100 90

N.m 190

80 70

170

60

150

50

130

Output

Torque

"

145EG45

40 30 20 10 0 1000 2000 3000 4000 5000 6000 7000

Engine Speed (rpm)

145EG46

ENGINE – 3S-FE ENGINE

59

JMAJOR DIFFERENCES The following changes have been made to the 3S-FE Engine. Item

Features

Cooling System

An aluminum radiator core is used for weight reduction.

Intake and Exhaust System

D The ports of the intake manifold have been extended to improve torque in the low- to mid-speed range. D A ball joint has been adopted in the front exhaust pipe to reduce noise and vibration. D The internal construction of the main muffler has been optimized to improve its quietness and reduce the exhaust pressure. For details, see page 34. D The support of the main muffler has been changed from the 3-point to 2-point support to reduce the noise and vibration that are transmitted to the body.

Fuel System

A fuel returnless system has been adopted to reduce evaporative emissions*. For details, see page 34.

Ignition System

D The DIS (Direct Ignition System) is used to enhance the reliability of the ignition system.

Engine Control System

D The fuel injection system is changed from a 2-group injection type to sequential multiport fuel injection type. D The power steering idle-up control has been changed from the system using an air control valve to the one using a pressure switch and an ISC valve. D The radiator cooling fan is now controlled by the engine ECU. D M-OBD (Multiplex On-Board Diagnosis) system is adopted. For details, see page 40.

*: Only for Europe Model

EG

60

ENGINE – 3S-FE ENGINE

JINTAKE AND EXHAUST SYSTEM 1. Intake Manifold The low- to mid-speed range torque has been improved by increasing the diameter and the length of the intake manifold port and by reducing the intake air chamber capacity.

150EG64

New

Previous

JIGNITION SYSTEM 1. General Similar to the 4A-FE engine, the DIS (Direct Ignition System) has been adopted to improve the reliability of the ignition system. To High-Tension Cord Front

Secondary Coil High-Tension Cords

Igniter

Plug Caps Ignition Coils (with Igniter)

Core

Primary Coil

Connector

Ignition Coil Cross Section 150EG65

141EG07

61

ENGINE – 3S-FE ENGINE

2. Spark Plugs Twin ground electrode spark plugs are used on the 3S-FE engine. Due to the adoption of the DIS system, the number of sparks produced is double that produced in the conventional ignition system. To maintain spark plug durability, the ground electrodes have been made bipolar. "

Recommended Spark Plugs A DENSO

K20TR11

NGK

BKR6EKB11

Plug Gap

1.0 – 1.1 mm (0.039 – 0.043 in.)

EG

Ground Electrodes 141EG08

62

ENGINE – 3S-FE ENGINE

JENGINE CONTROL SYSTEM 1. General The 3S-FE engine has adopted the sequential multiport fuel injection system for its engine control system as well as an M-OBD (Multiplex On-Board Diagnosis) system. The engine control system of new 3S-FE engine and previous 3S-FE engine are compared below. System

Outline

New

Previous

A D-type EFI system is used, which indirectly detects intake air volume by manifold pressure sensor signal.

f

f

The fuel injection system is a sequential multiport fuel injection system.

f

–

The fuel injection system is a 2-group type, each of which injects 2 cylinders simultaneously.

–

f

Ignition timing is determined by the engine ECU based on signals from various sensors.

f

f

It retards ignition timing to suppress knocking if it occurs.

f

f

In vehicles equipped with automatic transaxle, torque control compensation during gear shifting is used to minimize the shift shock.

f

f

ISC (Idle Speed Control)

A rotary solenoid type ISC valve is used, which controls the fast idle and idle speeds.

f

f

Fuel Pump Control

Fuel pump operation is controlled by signal from the engine ECU.

f

f

Oxygen Sensor Heated Control

Maintains the temperature of the oxygen sensor at an appropriate level to increase accuracy of detection of the oxygen concentration in the exhaust gas.

f

f

EGR Cut-Off Control

The EGR is cut off under light engine loads or low temperature conditions to maintain driveability.

f

f

Air Conditioning Cut-Off Control

By controlling the air conditioning compressor in accordance with the throttle valve opening angle and the vehicle speed, driveability is maintained.

f

f

Cooling Fan Control

Radiator cooling fan operation is controlled by signals from engine ECU based on the water temperature sensor signal (THW).

f

–

When the engine ECU detects a malfunction, the engine ECU diagnoses and memorizes the failed section.

f

f

A newly developed diagnostic system which utilizes a high speed bi-directional communication line to provide extended diagnostic capabilities and features.

f

–

When the engine ECU detects a malfunction, the engine ECU stops or controls the engine according to the data already stored in memory.

f

f

EFI Electronic Fuel Injection

ESA Electronic Spark Advance

Diagnosis

Fail-Safe

63

ENGINE – 3S-FE ENGINE

2. Construction The configuration of the engine control system in the new 3S-FE engine is as shown in the following chart. differ from the previous 3S-FE engine. Shaded portions SENSORS

ACTUATORS PIM

MANIFOLD PRESSURE SENSOR

EFI #10

CRANKSHAFT POSITION SENSOR D Engine Speed Signal D Crankshaft Angle Signal

#20

NE

#30 #40

CAMSHAFT POSITION SENSOR

IGNITERS IGF

THA

IGNITION COILS SPARK PLUGS

THROTTLE POSITION SENSOR

VTA

D Throttle Position Signal

ISC

IGNITION SWITCH

STA

ISCO ISCC

SPD

FC

D Starting Signal COMBINATION METER

OX

HEATED OXYGEN SENSOR*1

Engine ECU

VAF

VARIABLE RESISTOR*2

CONTROL VALVE FUEL PUMP CONTROL

D Vehicle Speed Signal

CIRCUIT OPENING RELAY OXYGEN SENSOR HEATER CONTROL*1

HT

OXYGEN SENSOR HEATER

KNK

KNOCK SENSOR FUEL CONTROL CONNECTOR*2

AIR CONDITIONING CUT-OFF CONTROL

R/P ACT

NEUTRAL START SWITCH*3

NSW 2, L

D Neutral Start Signal D Shift Lever Position Signal

ELS1

POWER STEERING OIL PRESSURE SWITCH

PSSW

AIR CONDITIONING AMPLIFIER

AIR CONDITIONING AMPLIFIER EGR CUT-OFF CONTROL*1

B/K

SWITCH*3

TAILLIGHT & FRONT AND REAR WINDOW DEFOGGER

EGR

VSV COMBINATION METER

THWO

AC1

ENGINE COOLANT TEMP. GAUGE COOLING FAN CONTROL

FAN

IMI IMO SIL TC

W +B

EFI MAIN RELAY *1: *2: *3:

NO.4 INJECTOR ESA

INTAKE AIR TEMP. SENSOR

DATA LINK CONNECTOR 3

NO.3 INJECTOR

IGT1,IGT2

THW

WATER TEMP. SENSOR

IMMOBILISER ECU*1

NO.2 INJECTOR

G

D Crankshaft Angle Signal

STOP LIGHT

NO.1 INJECTOR

Only for Europe Model Only for General Countries Model Applicable only to the Automatic Transaxle Model.

BATT BATTERY

COOLING FAN RELAY CHECK ENGINE LAMP

EG

64

ENGINE – 3S-FE ENGINE

3. Engine Control System Diagram

Neutral Start Switch*3 Ignition Switch Fuel Return*2

Vehicle Speed Sensor Air Conditioning Amplifier DLC3

Fuel Pump

Charcoal Canister

Fuel Filter

Check Engine Lamp Engine ECU

Battery Electronic Load Signal

VSV*1 (for EGR) Igniters

Intake Air Temp. Sensor

BVSV

Camshaft Position Sensor

Throttle Position Sensor ISC Valve

Injector

Knock Sensor

Manifold Pressure Sensor

EGR Valve*1

Water Temp. Sensor

Heated Oxygen Sensor*1

EGR Vacuum Modulator*1 TWC Crankshaft Position Sensor

145EG29

*1: Only for Europe Model *2: Only for General Countries Model *3: Automatic Transaxle Model Only

Heated Oxygen *1 : Only for Europe Model Sensor* 1 *2 : Only for Genral Countries Model *3 : Applicable only to Automatic Transaxle Model

Water Temp. Sensor

Knock Sensor

Camshaft Position Sensor

Manifold Pressure Sensor

Engine ECU

Neutral Start Switch*3

Throttle Position Sensor

Ignition Coil (with Ignition) 145EG30

ISC Valve

DLC3

Combination Meter

Intake Air Temp. Sensor

Variable Resistor* 2

ENGINE – 3S-FE ENGINE 65

4. Layout of Components

EG

66

ENGINE – 3S-FE ENGINE

5. Main Components of Engine Control System The following table compares the main components of the 3S-FE engine in the new and previous model. Model

New

Previous

Semiconductor Type

z

Linear Type

z

Crankshaft Position Sensor

Pick-Up Coil Type, 1

–

Camshaft Position Sensor

Pick-Up Coil Type, 1

–

Crankshaft Position Sensor

–

Pick-Up Coil Type, 1

Camshaft Position Sensor

–

Pick-Up Coil Type, 1

Knock Sensor

Built-In Piezoelectric Element Type, 1

z

Oxygen Sensor

With Heater Type

z

4-Hole Type

2-Hole Type

Rotary Solenoid Type

z

Component Manifold Pressure Sensor Throttle Position Sensor

Distributor

Injector ISC Valve Camshaft Position Sensor

The camshaft position sensor is mounted onto the cylinder head. Using the protrusion that is provided on the timing pulley, the sensor generates 1 signal for every revolution. This signal is then sent to the engine ECU as a crankshaft angle signal. Protrusion

Camshaft Timing Pully

Camshaft Position Sensor

145EG31

67

ENGINE – 3S-FE ENGINE Crankshaft Position Sensor

The crankshaft position sensor is mounted on the oil pump body. The timing rotor is integrated with the crankshaft pulley. The rotor’s teeth are spaced 10_ apart according to crankshaft angle but since there are 2 teeth missing, as illustrated below, there is a total of 34 teeth. Accordingly, the engine ECU can detect the crankshaft angle in addition to the crankshaft speed.

EG

Timing Rotor

Crankshaft Position Sensor

145EG32

6. EFI (Electronic Fuel Injection System) The injection pattern has been changed from the previous 2-group injection type to the Sequential Multiport fuel injection type to improve the precision of the air-fuel ratio feedback control.

7. ISC (Idle Speed Control) The power steering idle-up control has been changed from the system using an air control valve to the one using a pressure switch and an ISC valve.

8. Cooling Fan Control In the previous model, the operation of the cooling fan used to be controlled by the water temperature switch provided at the bottom of the radiator lower tank. In the new model, the cooling fan is controlled by the engine ECU based on the signal (THW) that is output by the water temperature sensor.

9. Engine Coolant Temperature Signal Output In place of the temperature sender gauge used on the previous model, the engine ECU sends the engine coolant temperature signal to the engine coolant temperature gauge in the combination meter.

68

ENGINE – 2C-T AND 2C-TE ENGINES

2C-T AND 2C-TE ENGINES JDESCRIPTION Based on the 2C-T engine, the 2C-TE provides improved engine performance through the use of an intercooler, as well as improved driveability and reduced exhaust emissions through the use of an electronically controlled injection pump. In the 2C-T engine, the distance between the intake and exhaust valves in the cylinder head has been increased to improve the cooling performance between the valves.

145EG18

145EG19

69

ENGINE – 2C-T AND 2C-TE ENGINES

JENGINE SPECIFICATIONS AND PERFORMANCE CURVES Model Engine Item

New 2C-TE

2C-T

z

8-Valve, OHC, Belt Drive

z

Combustion Chamber

Swirl Type

z

Manifolds

Cross-Flow

z

Valve Mechanism

Distributor Type (Electronically Controlled)

Fuel System Displacement

cm3 (cu. in.)

Bore x Stroke

mm (in.) Europe

z

86.0 x 85.0 (3.39 x 3.35)

z

23.0 : 1

z

Max. Torque [EEC]

Intake Valve Timing Exhaust

66 kW@4000 rpm

60 kW/4000 rpm

61kW@4000 rpm

–

60 kW/4000 rpm

61 kW@4000 rpm

General Countries Europe

203 N.m@2200 rpm

170 N.m@2000X3000 rpm 174 N.m@2000X3000 rpm

–

170 N.m@2000X3000 rpm 174 N.m@2000X3000 rpm

General Countries Open

7_BTDC

z

Close

35_ABDC

33_ABDC

Open

56_BBDC

z

Close

5_ATDC

z

48 or higher

z

CF-4

API CD or Better

Fuel Cetane Number Oil Grade For Europe A

"

60

180

50

kW 70 N.m 180 Torque

N.m 220

40

100

30

3000

4000

Output

140

2000

For General Countries A

kW 70

: New (2C-TE) : Previous (2C-T)

1000

z

60

160 50

140 120

40

100

30

20

20

10

10

0

0

5000

1000

Engine Speed (rpm)

2000

3000

4000

Output

Max. Output [EEC]

Distributor Type (Mechanically Controlled)

1975 (120.5)

Compression Ratio

Torque

2C-T

4-Cylinder, In-Line

No. of Cyls. & Arrangement

"

Previous

5000

Engine Speed (rpm) 145EG38

145EG39

EG

70

ENGINE – 2C-T AND 2C-TE ENGINES

JMAJOR DIFFERENCES The following changes have been made to the 2C-TE and 2C-T engine. Item

Features

2C-TE

2C-T

D The distance between the intake and exhaust valves in the cylinder head has been increased to improve the cooling performance. D The shape of the combustion chamber has been optimized to improve the torque in the low- to mid-speed range.

f

f

D A diesel throttle has been adopted to reduce intake air noise and vibration. D An intercooler has been adopted to improve engine performance. D The exhaust manifold adopts a two-part construction to improve its reliability.

f

–

D The internal construction of the main muffler has been optimized to improve its quietness and reduce the exhaust pressure. D The support of the main muffler has been changed from the 3-point to 2-point support to reduce the noise and vibration that are transmitted to the body.

f

f

Turbocharger System

The size of the vanes and the clearance between various parts have been optimized to improve the turbocharging efficiency.

f

–

Cooling System

An aluminum radiator core is used for weight reduction.

f

f

Fuel System

An electronically controlled injection pump is used.

f

–

Engine Control System

D An electronic fuel injection system has been adopted. D M-OBD (Multiplex On-Board Diagnosis) system is adopeted.

f

–

Engine Proper

Intake and Exhaust System

71

ENGINE – 2C-T AND 2C-TE ENGINES

JENGINE PROPER 1. Cylinder Head The distance between the intake and exhaust valves has been increased to improve the cooling performance.

Increased

Intake

Exhaust

EG 145EG40

2. Cylinder Block and Crankshaft (Only for 2C-TE ENGINE) Along with the adoption of the engine control system, a crankshaft position sensor has been provided in the cylinder block, and a protrusion has been provided on the crankshaft to generate a signal. Protrusion

Crankshaft Position Sensor Cylinder Block

Crankshaft 141EG21

141EG22

72

ENGINE – 2C-T AND 2C-TE ENGINES

JINTAKE AND EXHAUST SYSTEM 1. Diesel Throttle (Only for 2C-TE Engine) D The throttle valve that is not linked directly to an accelerator pedal has been adopted to reduce the noise and vibration during idling, deceleration, and when the engine is stopped. D The throttle valve opening is controlled by the engine ECU in accordance with the engine condition, in the following 3 stages: wide open, idle opening, and fully closed.

145EG48

2. Intercooler (Only for 2C-TE Engine) An intercooler has been adopted to improve engine performance. The intercooler is provided in the left side of the front bumper.

Intercooler 145EG41

3. Exhaust Manifold (Only for 2C-TE Engine) The exhaust manifold adopts a two-part construction in which the two parts are connected by a bellows to improve the manifold’s reliability.

Bellows

145EG53

73

ENGINE – 2C-T AND 2C-TE ENGINES

3. Exhaust Pipe The outlet pipe in the main muffler has been extended and various components have been optimally located to improve quietness and reduce the exhaust pressure.

: Extended portion Outlet Pipe

Exhaust Gas

145EG42

EG JFUEL SYSTEM 1. Injection Pump (Only for 2C-TE Engine) Along with the adoption of the engine control system, a spill control valve, timing control valve, fuel temperature sensor, engine speed sensor, and injection pump calibration unit have been provided. Engine Speed Sensor Fuel Temp. Sensor

Spill Control Valve

Injection Pump Calibration Unit

Timing Control Valve 145EG47

74

ENGINE – 2C-T AND 2C-TE ENGINES

JENGINE CONTROL SYSTEM (ONLY FOR 2C-TE ENGINE) 1. General To operate the engine is an optimal condition. The engine control system of the 2C-TE engine have general control of the following functions: fuel injection volume control, fuel injection timing control and idle speed control. In addition, a diagnosis function has been added to improve the serviceability of the engine. System

Outline

Fuel Injection Volume Control

Based on the signals received from the sensors, the engine ECU determines the fuel injection volume in accordance with the engine condition.

Fuel Injection Timing Control

Based on the signals received from the sensors, the engine ECU determines the fuel injection timing in accordance with the engine condition.

Idle Speed Control

The engine ECU determines the idle speed in accordance with the engine condition, and controls the fuel injection volume in order to achieve the target idle speed.

Stable Idling Control

Corrects the fuel injection volume that is directed to each cylinder during idling, thus reducing engine vibration.

Diesel Throttle Control

Controls the throttle valve opening in 3 stages 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 coolant temperature.

EGR Control

Controls the engine EGR volume in accordance with the engine condition.

Air Conditioning Cut-Off Control

By controlling the air conditioning compressor ON or OFF in accordance with the engine condition, drivability is maintained.

Engine Immobiliser

Prohibits fuel delivery if an attempt is made to start the engine with an invalid ignition key.

Diagnosis

D When the engine ECU detects a malfunction, the engine ECU diagnoses and memorizes the failed section. D A newly developed diagnostic system which utilizes a high speed bi-directional communication line to provide extended diagnostic capabilities and features.

Fail-Safe

When the engine ECU detects a malfunction, the engine ECU stops or controls the engine according to the data already stored in memory.

75

ENGINE – 2C-T AND 2C-TE ENGINES

2. Construction The configuration of the engine control system which can be broadly divided into three groups: the engine ECU, the sensors and the actuators, is shown in the following chart. SENSORS

ACTUATORS

TURBO PRESSURE SENSOR

FUEL INJECTION VOLUME CONTROL

PIM

D Intake Manifold Pressure Signal ENGINE SPEED SENSOR

SPV

SPILL CONTROL VALVE

NE

D Engine Speed Signal CRANKSHAFT POSITION SENSOR

FUEL INJECTION TIMING CONTROL

TDC

TCV

D Crankshaft Angle Signal

TIMING CONTROL VALVE

THW

WATER TEMP. SENSOR

GLOW PLUG CONTROL

THA

INTAKE AIR TEMP. SENSOR

G-IND

THF

FUEL TEMP. SENSOR ACCELERATOR PEDAL POSITION SENSOR

SREL

VA,VAS

ACCELERATOR PEDAL SWITCH D Accelerator Pedal Fully Closed Signal

GLOW PLUG RELAY

DIESEL THROTTLE CONTROL

IDL

D Idling Signal D Accelerator Pedal Position Signal

GLOW INDICATOR LAMP

S / LU Engine ECU

S / TH

VSV (Idle Opening) VSV (Fully Closed)

PDL EGR CONTROL DATA

INJECTION PUMP CALIBRATION UNIT

EGR

VACUUM REGULATING VALVE

CLK PA

IGNITION SWITCH

STA

D Starting Signal (ST Terminal) D Ignition Signal (IG Terminal)

VSV (for Turbo Pressure Sensor)

IGSW

COMBINATION METER

AIR CONDITIONING CUT-OFF CONTROL

SP1 ACT

D Vehicle Speed Signal BLOWER SWITCH

AIR CONDITIONING AMPLIFIER

BLM

D Blower Switch Signal

COMBINATION METER

AIR CONDITIONER AMPLIFIER

AC1

D A / C Switch Signal IMI

THWO MREL

MAIN RELAY

IMMOBILISER ECU IMO TC

DATA LINK CONNECTOR 3

W CHECK ENGINE LAMP

SIL +B

MAIN RELAY

ENGINE COOLANT TEMP. GAUGE

BATT BATTERY

EG

76

ENGINE – 2C-T AND 2C-TE ENGINES

3. Engine Control System Diagram Accelerator Pedal Position Sensor

Engine Speed Sensor Accelerator Pedal Switch

Spill Control Valve Fuel Temp. Sensor

Injection Pump Calibration Unit

Vehicle Speed Signal Ignition Switch Signal Blower Switch Signal Air Conditioner Signal

Engine ECU

VSV1 for Main Actuator

Timing Control Valve Vacuum Regulating Valve

VSV for Sub Actuator Intake Air Temp. Sensor

InterCooler

Turbo Pressure Sensor

Turbocharger VSV for Turbo Pressure Sensor

Water Temp. Sensor EGR Valve Crankshaft Position Sensor

145EG44

EGR Valve

Injection Pump

Vacuum Regulating Valve

Turbo Pressure Sensor

VSV2 (for Sub Actuator)

VSV for Turbo Pressure Sensor

Water Temp. Sensor

Engine ECU

Crankshaft Position Sensor

Glow Plug

Intake Air Temp. Sensor

VSV1 (for Main Actuator)

145EG43

Sub Actuator (for Diesel Throttle)

Main Actuator for Diesel Throttle

DLC3

ENGINE – 2C-T AND 2C-TE ENGINES 77

4. Layout of Components

EG

78

ENGINE – 2C-T AND 2C-TE ENGINES

5. Main Components of Engine Control System Turbo Pressure Sensor The turbo pressure sensor consists of a semiconductor which utilizes the characteristic of a silicon chip that changes its electrical resistance when pressure is applied to it. The sensor converts the intake air pressure into an electrical signal, and sends it to the engine ECU in an amplified form. In addition, the atmospheric pressure can be detected by switching the piping passage through the operation of the VSV.

Output Voltage

V 5

0

60 86.7 (450) (650)

206.7 kPa (1550) (mmHg)

Absolute Pressure Turbo Pressure Sensor Output Characteristics

141EG26

Engine Speed Sensor The engine speed sensor is attached to the roller ring in the injection pump to detect the engine speed. The timing rotor is attached to the drive shaft. Missing 2 teeth at each of the 4 locations, the timing rotor generates a signal every 11.25_ (crankshaft angle) with its 56 teeth.

Engine Speed Sensor Roller Ring

Output Voltage

360_CA* 11.25_CA* + " 0 # –

Drive Shaft

Timing Rotor

141EG44

*: CA (Crankshaft Angle)

141EG45

79

ENGINE – 2C-T AND 2C-TE ENGINES Crankshaft Position Sensor The crankshaft position sensor is attached to the cylinder block. Using the protrusion that is provided on the crankshaft, the sensor generates 1 signal for every revolution. This signal is then sent to the engine ECU as a crankshaft position signal. Crankshaft Position Sensor

To Engine ECU

Crankshaft

EG

Protrusion 141EG46

Fuel Temperature Sensor The fuel temperature sensor is attached to the injection pump, and uses an internal thermistor to detect the fuel temperature.

Fuel Temp. Sensor

Fuel Pump Calibration Unit To compensate for the shift in injection volume and injection timing caused by the variances in the injection pump itself, a correction is made by using the data that is stored in the ROM in the fuel pump calibration unit.

Fuel Pump Calibration Unit 145EG47

Timing Control Valve The timing control valve is attached to the injection pump. In accordance with the signals from the engine ECU, it opens the valve in the fuel passage between the high-pressure chamber and the low-pressure chamber, thus controlling the injection timing. When the current flows to the coil of the timing control valve, the starter core becomes an electromagnet to push and compress the spring. This causes the moving core to retract and open the fuel passage.

Moving Core

Coil

Fuel Passage

Valve Spring Starter Core 145EG54

80

ENGINE – 2C-T AND 2C-TE ENGINES Spill Control Valve The spill control valve is attached to the injection pump to control the fuel injection volume in a accordance with the signals received from the engine ECU. When the current applied to the spill control valve is shut off, the valve in the spill control valve opens by the difference in pressures. Thus, the pressure in the plunger decreases causing the injection nozzle to stop injection fuel. The length of time till the spill control valve is turned OFF becomes the fuel injection time. Thus, the fuel injection volume is controlled by increasing or decreasing the length of time till the spill control valve is turned OFF.

Spill Passage

Return

Plunger

To Injection Nozzle 141EG48

Accelerator Pedal Position Sensor D The accelerator pedal position sensor uses a hall element that outputs voltage that changes linearly in relation to the amount of pedal effort that is applied to the accelerator pedal. The accelerator pedal position sensor uses a duplex system to ensure its reliability. D An idle switch that detects the fully closed condition of the accelerator pedal is enclosed in the accelerator pedal position sensor.

Accelerator Pedal Switch

Accelerator Pedal Position Sensor

Accelerator Pedal

Accelerator Pedal Switch Detects the fully closed condition of the accelerator pedal. 145EG50

81

ENGINE – 2C-T AND 2C-TE ENGINES

6. Fuel Injection Volume Control Based on sensor signals, the engine ECU controls the fuel injection volume by calculating the fuel injection volume that is appropriate for the engine condition. Spill Control Valve Injection Pump Engine Speed Signal Water Temp. Signal Accelerator Pedal Position Signal Intake Air Temp. Signal Intake Manifold Pressure Signal Fuel Temp. Signal Atomosphere Pressure Signal Fuel Pump Calibration Unit Signal

Engine ECU

To Injection Nozzle

EG

141EG50

Function of Engine ECU The engine ECU calculates the basic injection volume based on the throttle opening and engine speed, and the maximum injection volume for the engine condition. The two injection volumes are then compared, and the lesser of the two is selected. A correction value, which is obtained via the correction resistors, is added to that injection volume, thus determining the final injection volume. 1) Basic Injection Volume Determined in accordance with the throttle opening and the engine speed. 2) Maximum Injection Volume Based on the signals received from the sensors, correction values are added to the theoretically required injection volume (basic maximum injection volume) to determine the maximum injection volume during engine operation. a. Basic Maximum Injection Volume Determined in accordance with the engine speed. b. Intake Manifold Pressure Correction Corrects the basic maximum injection volume in accordance with the intake manifold pressure. The higher the intake manifold pressure becomes, the larger the injection volume becomes.

82

ENGINE – 2C-T AND 2C-TE ENGINES c. Intake Air Temperature Correction Corrects the variance in the air-fuel ratio that is created by the difference in the density of the intake air in accordance with the intake air temperature. The higher the intake air temperature becomes, the smaller the injection volume becomes. d. Fuel Temperature Correction Corrects the variance in the injection volume that is created by the difference in the density of the fuel in accordance with the fuel temperature. The higher the fuel temperature becomes, the larger the injection volume becomes. 3) Starting Injection Volume Control Determines the fuel injection volume during starting in accordance with the starting signal and the water temperature signal. When the engine is cold, the lower the coolant temperature becomes, the larger the injection volume becomes.

7. Fuel Injection Timing Control Based on the signals received from the sensors, the engine ECU calculates and controls the fuel injection timing to be optimal for the engine condition.

Injection Pump Engine Speed Signal Water Temp. Signal Accelerator Pedal Position Signal Intake Air Temp. Signal Intake Manifold Pressure Signal Atomosphere Pressure Signal Fuel Pump Calibration Unit Signal

Engine ECU

Timer Piston

To Injection Nozzle

Timing Control Valve 141EG50

Function of Engine ECU The engine ECU adds the corrections from the sensor signals to the basic fuel injection timing to calculate the fuel injection timing that is optimal for the engine condition. 1) Basic Injection Timing The basic injection timing is determined in accordance with the injection volume and the engine speed.

ENGINE – 2C-T AND 2C-TE ENGINES

83

2) Injection Timing Correction a. Intake Manifold Pressure Correction Corrects the basic fuel injection timing in accordance with the intake air pressure. The injection timing is advanced when the intake air pressure is low in such the case as of high altitude areas. b. Water Temperature Control Corrects the basic fuel injection timing in accordance with the water temperature. The injection timing is advanced when the water temperature is low. 3) Starting Injection Timing Control The starting injection timing is determined in accordance with the starting signal, water temperature signal, and engine speed. The injection timing is advanced when the water temperature is low and engine speed is high.

8. Idle Speed Control D In this system, the engine ECU calculates the target engine speed in accordance with the engine condition, and determines the fuel injection volume, thus controlling the idle speed rpm. D During cold operation, the idle is increased by turning ON the blower switch, thus improving the heating performance of the heater. Spill Control Valve Injection Pump Engine Speed Signal Water Temp. Signal Accelerator Pedal Position Signal Vehicle Speed Signal

Engine ECU

A / C Switch Signal Staring Signal Blower Switch Signal Fuel Pump Calibration Unit Signal

To Injection Nozzle

141EG50

Function of Engine ECU 1) Feedback Control During idling, the feedback control controls the injection volume to achieve the target idle speed, if there is a difference between the target idle speed calculated by the engine ECU and the actual idle speed.

EG

84

ENGINE – 2C-T AND 2C-TE ENGINES 2) Warm-Up Control Controls the injection volume during warm-up to achieve an optimal fast idle speed in accordance with water temperature. 3) Engine Speed Change Estimate Control Immediately after the air conditioning switch is engaged, the idle speed can be affected by the change in the load that is applied to the engine. To prevent this symptom, the engine speed-change estimate control increases or decreases the injection volume before the idle speed changes.

9. Stable Idling Control Immediately after the air conditioning switch is turned ON or OFF, the load applied to the engine changes, causing the idle speed to fluctuate. To prevent this symptom, the engine speed-change estimate control increases or decreases the injection volume before the idle speed fluctuates.

10. Diesel Throttle Control The opening of the throttle valve that is installed on the intake manifold is controlled by the engine ECU in accordance with the engine condition, in the following 3 stages: wide open, idle opening, and fully closed. As a result, the noise that is generated during idling and deceleration, as well as the noise and vibration that are generated when the engine is stopped, have been reduced. "

System Diagram A Actuator (Main) VSV 1 From Vacuum Pump

Throttle Valve Engine ECU

Engine Speed Signal Water Temp. Signal Accelerator Pedal Position Signal Atomosphere Pressure Signal

VSV 2 Actuator (Sub)

145EG49

VSV VSV 1

VSV 2

Wide Open

OFF

OFF

Idle Opening

ON

OFF

Fully Closed

ON

ON

Throttle Valve

85

ENGINE – 2C-T AND 2C-TE ENGINES

11. EGR Control In the EGR control system, the engine ECU controls the vacuum regulating valve to recirculate an appropriate amount of exhaust gas to the combustion chamber in accordance with the engine condition. This results in slower combustion rate, lower combustion temperature, and reduced NOx emissions. "

System Diagram A Vacuum Pump Vacuum Damper Vacuum Regulating Valve Intake

Engine ECU

Water Temp. Signal Engine Speed Signal Throttle Position Signal Intake Air Pressure Signal

EGR Valve Engine

Exhaust 141EG31

Construction 1) Vacuum Regulating Valve Controls the vacuum that is applied by the vacuum pump to the EGR valve in accordance with the signals from the engine ECU. To EGR Valve From Vacuum Pump

Atomosphere

145EG51

EG

86

ENGINE – 2C-T AND 2C-TE ENGINES 2) EGR Valve Using the vacuum from the vacuum regulating valve, the EGR valve opens and closes the valve to introduce exhaust gas into the intake manifold.

From Vacuum Regulating Valve

To Intake Manifold

From Exhaust Manifold 145EG52

Operation 1) Based on the signals from the sensors, the engine ECU applies duty control to the current that is applied to the vacuum regulating valve, thus regulating the vacuum that is applied to the EGR valve. Thus, the EGR valve opening is controlled to provide the volume of EGR gas that is appropriate for the engine condition. 2) The EGR function is stopped under the conditions given below to ensure drivability and to reduce diesel smoke. D The water temperature is below 60_C (140_F). D The vehicle is driven under high load condition. D During decelecration (The EGR operates at idle)

11. Engine Immobiliser System The engine immobiliser system has been designed to prevent the vehicle from being stolen. This system uses a transponder key computer that stores the ID code of the authorized ignition key. If an attempt is made to start the engine using an unauthorized key, the transponder key computer emits a signal to the engine ECU to prohibit fuel delivery effectively in order to disable the engine. For details, see page 151 in the Engine Immobiliser system section.

12. Diagnosis D If the engine ECU detects any problem with a sensor or an electrical circuit, it turns ON the CHECK ENGINE lamp in the combination meter to inform the driver. In addition, the malfunction code will be stored in memory. D An M-OBD (Multiplex On-Board Diagnostic) System has been adopted to improve serviceability. For details, see page 40.