24/09/2016

ToyotaNRseriesengines

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ToyotaNRseriesengines
ReadinRussian

Eugenio,77
mail@toyotaclub.net
ToyotaClub.Net
Jan2013Feb2016

ThepriorityinthecreationandproductionofnewsmalldisplacementseriesbelongedtoDaihatsudepartment,
butNRaremostknownasenginesofToyotamodels.Firstengineoftheseries1NRFEintroducedin2008for
European market. It immediately replaced outdated 4ZZFE at overseas market and then gradually supplanted
2NZFEand2SZFEatdomesticmarket.Overtime,theothermodificationsbegantodisplaceoldgood1NZFE.
Atmid2010sitinstalledinA/B/Cclasscars.
Displacement,
cm3
1NRFE
1329
1NRFE
1329
1NRFKE
1329
1NRVE
1329
2NRFE
1496
2NRVE
1496
2NRFKE
1496
3NRFE
1197
3NRFE
1197
4NRFE
1329
5NRFE
1496
6NRFE
1329
7NRFE
1496
8NRFTS
1197
Engine

Perfeccionismo ser exigente.

BorexStroke,mm
72.5x80.5
72.5x80.5
72.5x80.5
72.5x80.5
72.5x90.6
72.5x90.6
72.5x90.6
72.5x72.5
72.5x72.5
72.5x80.5
72.5x90.6
72.5x80.5
72.5x90.6
71.5x74.5

Compression
ratio
11.5
11.5
13.5

10.5

13.5
10.5
11.5
11.5
11.5
11.5
11.5
10.0

Output,hp

Torque,Nm

RON

Sys

Market

99/6000
95/6000
99/6000
95/6000
90/5600
104/6000
109/6000
80/5600
86/6000
99/6000
107/6000
99/6000
107/6000
115/5200

132/3800
119/4000
121/4400
120/4200
132/3000
139/4200
136/4400
104/3100
108/4000
123/4200
140/4200
123/4200
140/4200
185/15004000

95
91
91

91

95

EFI
EFI
EFI
EFI
EFI
EFI
EFI
EFI
EFI
EFI
EFI
EFI
EFI
D4T

EEC
JIS
JIS

Ind

JIS
Ind

CHN
CHN
CHN
CHN
EEC

DESCUBRA SEU VOLKSWAGEN

Volkswagen

1NRFE (1.3 EFI DVVT) basic motor transverse layout, multipoint injection, variable valve timing for both camshafts. Installed in:
Auris150..180,Corolla150..180,CorollaAxio160,iQ10,Passo30,Porte/Spade140,Probox/Succeed160,Ractis120,UrbanCruiser,
VersoS,Vitz130,Yaris130,DaihatsuBoon,Charade,SubaruTrezia,AstonMartinCygnet.
1NRFKE(1.3EFIDVVTiE)multipointinjection,VVTiEandMiller/Atkinsoncycleoperationmode.Installedin:Ractis120,Vitz130,
SubaruTrezia.
1NRVE (1.3 EFI DVVT) multipoint injection, variable valve timing for both camshafts. Daihatsu version for their own development
models.Installedin:Avanza650,DaihatsuXenia.
2NRFE(1.5EFI)type'10multipointinjection,withoutvariablevalvetiming.SimplifiedversionsforIndianmarket,withoutVVTandlash
adjusters.Installedin:Etios/EtiosCross.
2NRVE (1.5 EFI DVVT) type'13 multipoint injection, variable valve timing for both camshafts. Daihatsu version for their own
developmentmodels.Installedin:Avanza650.
2NRFKE (1.5 EFI DVVTiE) multipoint injection, VVTiE and Miller / Atkinson cycle operation mode. Installed in: Corolla Axio 160,
CorollaFielder160,Porte/Spade140,Sienta170,MitsuokaRyugi.
3NRFE(1.2EFI)type'10multipointinjection,withoutvariablevalvetiming.SimplifiedversionsforIndianmarket,withoutVVTandlash
adjusters.Installedin:EtiosLiva/Cross.
3NRFE(1.2EFIDVVT)type'13multipointinjection,variablevalvetimingforbothcamshafts.Installedin:Yaris150.
4NRFE(1.3EFIDVVT)analogueof1NRFEforChinesemarket.Installedin:Vios150CHN.
5NRFE(1.5EFIDVVT)analogueof2NRVEforChinesemarket.Installedin:Vios150CHN.
6NRFE(1.3EFIDVVT)analogueof1NRFEforChinesemarket.Installedin:Yaris150CHN.
7NRFE(1.5EFIDVVT)analogueof2NRVEforChinesemarket.Installedin:Yaris150CHN.
8NRFTS(1.2D4TDVVTiW)directinjection,turbocharged,VVTiWandMiller/Atkinsoncycleoperationmode.Installedin:Auris180.

1NRFE(1.3EFI)

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Enginemechanical
The cylinder block aluminium "open deck" with thin cast iron liners. The liners are fused into block and their
specialroughoutersurfacepromotesstrongconnection.Thewallthicknessbetweenthecylinders7mmonly,no
overhaulwithreboringprovidedbymanufacturer.

Theaxisofthecrankshafthasbeenshiftedby8mmrelativetothecylinderaxislines("desaxage"),thusreducing
thelateralcomponentoftheforceexertedbythepistontothecylinderwall,reducingwear.

Thereisthespacerinthewaterjacketinstalled,itallowsmoreintensivecoolantcirculationnearthetopofthe
cylinder,whichimprovesheatdissipationandhelpstomoreevenlythermallyload.

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Thecrankshafthas4balanceweights,narrowedjournalsandindividualmainbearingcaps.
Pistonsalloy,compactTshapedinprojection,withcuttedskirt.Thegroovefortheuppercompressionringis
anodized, the edge of the upper compression ring and oil scraper have antiwear PVD coating. A drawback
piston pins non fullfloating, but pressfitted into the connecting rod (except A series, this solution consistently
causesacceleratedwearandthenoise).
Thecamshaftsareinstalledinaseparatehousing,whichmountedonthecylinderheaditsimplifiesthedesign
andmanufacturingtechnologyofcylinderhead.
Therearehydrauliclashadjustersandrollerrockersinthevalvetrainmechanism."Indian"motorshaveoldstyle
adjustingtappets.
Theheadcoverismadeofplasticandprovidedwithoildeliverypipefortherockerslubrication.
Timingdrive16valveDOHC,drivenbysinglerowrollerchain(pitch8mm)withhydraulictensioner.
VVTactuatorsbothontheinletandoutletcamshaftsareinstalled(DVVTDualVariableValveTiming).Timing
variationsrange50forintakeand45forexhaust.

Thewaterpumpisinstalledincasttimingchaincover.

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Lubrication
Trochoidoilpumpisdrivenbycrankshaft.
Oilnozzlesthatlubricateandcoolthepistonsareprovided.

Theoilfilterismountedverticallyundertheengine.Usedthecollapsiblefilterwithreplaceablecartridges.
Coolingsystem
Coolingsystemisclassic:pumpdrivebyoutersideofserpentinebelt,"cold"(8084C)mechanicalthermostat,
heatedthrottlebody.

1thermostat2thermostathousing(plastic),3EGRvalve,4toheater,5toradiator,6fromheater,7fromradiator,8water
pump.

Versionsforcoldclimateareaareequippedwithcoolantheater(byexhaustgases).Inthecentralpipethevalve
actuatorwiththethermostatisintegrated:aftercoldstartinggasespassthroughtheheatexchanger,thenasthe
valveopensandtheheatinggasesalreadyflowtotheexhaust.

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Engine is equipped with separate fan motor control unit, which allows to adjust fan speed depending on the
coolanttemperature,refrigerantpressure,vehiclespeedandenginespeed.
Intakeandexhaust
Plasticintakemanifoldmountedatbulkheadside,steelexhaustmanifoldatfrontside.
AdrawbackEGRsystem,withvalvedrivenbysteppermotor.

Controlsystem(EFI)
Fuel injection traditional multipoint, sequential under normal conditions, at low temperature and low speed
groupedinjectioncanbeperformed.
Massairflowsensor(MAF)"hotwire"type,combinedwiththeintaketemperaturesensor.
Manifoldpreessuresensor(MAP)wasinstalledinEuro5modifications.
Throttlevalvefullyelectronicallycontrolled(ETCS):DCmotor,dualchannelnoncontactpositionsensor(Hall
effect).ETCSperformssomefunctionsoftractioncontrol(TRC)andstabilization(VSC).

Acceleratorpedalpositionsensordualchannelnoncontact(Halleffect).
Crankshaft and camshaft position sensors MRE type (magnetoresistive), provide a digital output signal and
workproperlyatlowenginespeed.
Knocksensorwideband"flat"piezoelectric,unliketheoldtypeofresonantknocksensorsitfeelsawiderrange
ofvibrationfrequencies.
Upstream catalyst planar type airfuel ratio (AFS) sensor (advantage rapid heating), downstream normal
oxygensensor.
Injectorswithelongatenozzleareinstalledinthecylinderheadandthefuelisinjectedascloseaspossibleto
theintakevalves.
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Fuelsupplywithoutreturnline.Inadditiontothepressureregulatorandlevelgaugesensor,EVAPcanisteris
combindewiththefuelpumpinthetank.

1absorber,2fuelpump,3fuelfilter,4pressureregulator,5fuellevelsensor.

Electrical
Ignition system DIS4 (separate coil for each cylinder). Spark plugs thin "iridium" SG20HR11 with long
threadedportion,hex14mm.
Thereareafewnewfeaturesinstartingsystem.SemiautomaticstartingitisenoughtoturnthekeytoSTART
and release, after which the control system automatically keeps the starter on until the engine start. When the
stopstartsystemisactive,thecontrolrememberscyclephaseforeachcylinderafterenginestall,soatrestart
thefuelandsparkaresuppliedthecylinderwhichisabletojoinintheworkimmediately.
Chargingsystemwithsegmentconductoralternators,80100Aoutput,onewayclutchinpulley.
Continuouslychargingofbatteryiscarriedoutduringdeceleration,butinsteadystatemodecyclesofcharging
anddischargingof the battery are alternates for maximum efficiency. Morecomplexcontrolsystemrequiredto
usethebatterytemperaturesensorandcurrentsensor.
Auxiliarydrivebysingleserpentinebeltwithautomatictensioner.
Experience
Theenginehavedisadvantagesarenotrelatedtoitsdesign:first,itdoesnotprovideadequatethrustweightratio
even for rather heavy Bclass cars and does not fit to modern Cclass cars second, at overseas market it is
usuallyaggregatedwithmanualgearbox.
Withregardtostructuraldefects,themanufacturerissuedonlyinstructionsrelatedtoincreasedoilconsumption
anddifficultstart.ButitisnotdifficulttodrawananalogywithotherseriesweaknessesVVTactuatorsaftera
coldstart,waterpumpleaks,excessivecarbondepositsduetoEGRoperation.

1NRFKE(1.3EFI)/2NRFKE(1.5EFI)

Amongthedifferencesfromthebaseenginenoting:
VariablevalvetimingsystemVVTiEseedetails.
ImplementedapossibilityofengineoperationbyMiller/Atkinsoncycleseedetails.
Highgeometriccompressionratio.
Exhaustpipeof421type.

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8NRFTS(1.2D4T)
Notefundamentalaspectsanddifferencesofthemotor,thatnotliketheotherenginesoftheseries.
Enginemechanical
VariablevalvetimingsystemVVTiWseedetails.
ImplementedapossibilityofengineoperationinMiller/Atkinsoncycleseedetails.
Strengtheningcylinderblock.

1cylinderblock,2thermostat(block),3cylinderbore.awaterpassage,brib,coilseparatechamber1,dknocksensorboss,f
waterjacket,gbreatherhole,iliner,jborehoning.

Crankshaftwith8counterweights.

1crankshaft,2thrustwasher,3bearing.amicrogrooved,boilgroove.

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1piston,2antifrictionringcarrier,3uppercompressionring,4lowercompressionring,5oilring,6expander.acombustion
chamber,bpolymercoating,ccompressionheight,ePVDcoating,fchromecoating.

1camshaftbearingcap,2camshafthousing,3cylinderhead.cwaterjacket(2stage),dintakeport.

Supplypumpdrivenbyadditionalcamoftheintakecamshaft.
Vacuumpumpdrivenbytheexhaustcamshaft(forbrakeboosteroperationandturbochargercontrol).

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1timingchaincover,2VVTisolenoid,3VVTiWsolenoid.

1intakecamshaftsprocket,2exhaustcamshaftsprocket,3VVTisolenoid,4VVTiWsolenoid,5exhaustcamshaft,6vacuum
pump,7intakecamshaft,8fuelpumpdrivingcam,9highpressurefuelpump,10valverocker,11valvestemcap,12valve
springretainerlock,13valvespringretainer,14valvespring,15valvespringseat,16valve,17lashadjuster.

Cylinderheadcovermadeofaluminium.

1cylinderheadcover,2oildeliverypipe,3baffleplate.

Appliedsodiumcooledvalves.
Theexhaustmanifoldisintegratedintothecylinderhead.

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Crankcaseventilationsystem.
Theboostmeansasincreasingtheamountofcrankcasebypassgasesandinabilitytoutilizeitbyconventional
methodusingtheintakevacuum.Therefore,theejectorismountedintheheadcover,soinboostmodegases
withhighcontentofhydrocarbonsdonotfallintotheatmospherebutreturntotheintakeandthenburninthe
cylinder.
Anotherseparatorchamberisinstalledtocrankcase.

1ejector,2PCVvalve,3oilseparatechamber.

Intheboostmodecrankcasegasesdischargedviatheejectortointake.

1aircleaner,2cylinderheadcover,3cylinderhead,4cylinderblock,5crankcase,6oilpan,7oilseparatechamber,8PCV
valve,9intakemanifold,10throttlebody,11intercooler,12turbocharger,13ejector.afreshair,bfreshair+blowbygas,c
ejectordrivegas.

The ejector operates on the principle of Venturi crankcase gases are sucked into the stream of flowing
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compressedair.

1nozzle.aairfromdownstreamofturbocharger,btoupstreamofturbocharger.

Withoutasignificantboost,crankcasegasesaresuckedthroughaconventionalPCVvalve.

1aircleaner,2cylinderheadcover,3cylinderhead,4cylinderblock,5crankcase,6oilpan,7oilseparatechamber,8PCV
valve,9intakemanifold,10throttlebody,11intercooler,12turbocharger,13ejector.afreshair,bfreshair+blowbygas.

Coolingsystem
Theengineisequippedbytwothermostats:
Traditional thermostat (opening temperature 8084C) in the water inlet controls the coolant flow through the
radiator
Thermostatonthecylinderblock(openingtemperature7680C)controlsthecoolantflowthroughtheblock,to
maximalfastwarmingup

1cylinderhead,2waterinlet,3thermostat(block),4cylinderblock,5waterpump,6throttlebody,7thermostat,8intercooler
reservetank,9radiator,10bleedervalve,11heaterradiator,12CVTfluidwarmer.

Builtincylinderheadexhaustmanifoldallowstocooltheexhaustgasesbeforeitsenteringtotheturbocharger.
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Lubrication
Unlike other engines with common nozzles for piston lubrication and cooling, the ECM can control the oil
injectiondependingonexternalconditions.

Coldengine/Warmedupengine

Reliefandcontrolvalvesareinstalledinoilpumpreliefvalvehousing.

1oilpumpreliefvalvehousing,2oilpressureswitchingvalve,3reliefvalve.

1oilpressureswitchingvalve.aclosed,bopened,ccoil,dplunger,eball,ffromoilpump,gtoreliefvalve.

1)Theoilsuppliedtotherearofthereliefvalve,cuttingofftheoilflowtothenozzles.

1reliefvalve,2oilcontrolvalve,3ECM,4nozzle.aengineoil.

2)Theoilflowtoreliefvalveendstops,thevalveopensandtheoilissuppliedtothenozzles.
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1reliefvalve,2oilcontrolvalve,3ECM,4nozzle.aengineoil,bdrain.

Engineoillevelsensorisinstalled.

1oillevelsensor,2oillevelswitch.aON,bOFF.

Intakeandexhaust

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1turbocharger,2airbypassvalve,3actuator,4wastegatevalve,5coil,6shaft,7valve,8compressorwheel,9turbine
wheel.cexhaustgas,dintakeair.

Boostpressurecontrolisperformedbyclassicwastegatevalve.
WhentheengineisstoppedWGTvalveopen.
When starting control valve shuts off the vacuum supply from the pump to the actuator, which in turn opens
WGT.Asaresult,thehotexhaustgasesflowdirectlyintotheconvertertoaccelerateitswarmup.
Atlowloads,whenthereisnoneedforaboost,openedWGTreducesresistanceandreducespumpinglosses
atexhaust.Byreducingtheamountofresidualgasthestabilityofthecombustionprocessisincreased.

1compressorwheel,2turbinewheel,3wastegatevalve,4actuator,5ECM,6vacuumregulatingvalve,7checkvalve2,8
vacuumpump.

AthighloadWGTisclosedandtheturbinecomesintoeffectiveoperation.

1compressorwheel,2turbinewheel,3wastegatevalve,4actuator,5ECM,6vacuumregulatingvalve,7checkvalve2,8
vacuumpump.

Air bypass valve serves to prevent a situation where the sudden closing of the throttle rouse to pressure
incresing between the turbocharger and the throttle, until the occurrence of reverse flow, accompanied by

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abnormalnoise.

1ECM,2airbypassvalve,3compressorwheel,4turbinewheel.atothrottlebody.

Independentturbochargercoolingcircuitwithanelectricpumpandownradiatorisused.

1electricwaterpump,2intercooler,3turbocharger,4intercoolerreservetank,5intercoolerradiator.

Intercoolerwaterairtype.

1intercooler,2intakemanifold,3innerfin.

ECMcontrolsthecoolantflowrateandcoolingefficiencybyelectricpumpspeed.

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Electricpump.ainlet,boutlet,crotor,dshaft.

Fuelinjectionsystem(D4T)

1ECM,2fuelpumpcontrolunit,3fueltank,4fuelpressureregulator,5fuelpump(lowpressure),6fuelpumpfilter,7charcoal
canister,8fuelsuctiontube,9fuelpump(highpressure),10fuelpressurepulsationdamper,11camshaft,12reliefvalve,13
checkvalve,14controlvalve,15fuelrail,16injector,17fuelpressuresensor.

Fuelinjectiondirectinthecombustionchamber,issynchronizedwithpistonposition.Thefuelfromtankpumpis
suppliedtohighpressurepump,thanunderpressureintothefuelrail,andfinallyintothecylindersbyinjectors.
Injectioncanbecarriedoutseveraltimesatthecycle.
Injection/supplypump.Singleplungerwithcontrolvalve,reliefvalve,checkvalveandpulsationdamperatinlet.
Mountedonthevalvecoveranddrevenby4lobescamofthecamshaft.Thefuelpressureisregulatedinthe
range2.420MPadependingondrivingconditions.

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1controlvalve,2rollerlifter,3fueltank,4fuelpressureregulator,5fuelpump(lowpressure),6fuelsuctionfilter,7fuelsuction
tube,8charcoalcanister,9fuelpump(highpressure),10fuelpressurepulsationdamper,11camshaft,12reliefvalve,13
plunger,14checkvalve,15fuelpressuresensor,16injector,17fuelrail.alowpressure,bhighpressure,chighpressurepipe.

Atinletstroke(A)theplunger2movesdownwardandfueldrawsintothepumpingchamber.
At the beginning of the compression stroke (B) part of the fuel is returned while control valve 1 is open (the
specifiedfuelpressureisset).
Attheendofthecompressionstroke(C)thecontrolvalveisclosedandthepressurizedfuelthroughthecheck
valve3issuppliedintothefuelrail.

Fuelrail.Madeofforgediron,containsfuelpressuresensortoprovidefeedback.

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1fuelpipe(highpressure),2fuelrail,3fuelpressuresensor,4injectorholder,5injector.

Injectors. Slotted nozzle injector injects the fuel into the cylinder as specific shaped spray that draws in a
significantamountofairandincreasesthemassadmission.Sealingteflon(PTFE)ringsfurtherreducevibration.

1Oring,2backupring,3insulator,4teflonseal.

Sparkplugs.NGKDILKAR8J9G,gap0.80.9mm.

Toyotaenginesreview
2000

PRISMA JOY 1.0 2017

PARCELAS DE
R$

499

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