Engine
Engine Overall
Engine Specification
Engine Proper
Valve Mechanism
Cooling System
Fuel System
Ignition System
Engine Mounting
Engine Control System
Engine
Engine Overall
• Engine number location
Engine
Engine Specification
Item K3-DE
No. of Cyls. & Arrangement 4-Cylinder, In-line
Valve Mechanism 16-Valve DOHC, Chain Drive
Displacement cm3 1297
Bore x stroke mm 72.0 X 79.7
Compression Ratio 10.0
Max. Output 63 kW @ 6000 rpm
Max. Torque 117 N·m@ 3200 rpm
Open 8° BTDC
Intake
Close 32° ABDC
Valve Timing
Open 30° BBDC
Exhaust
Close 2° ATDC
Fuel System D-type EFI
Ignition System Full Transistorized DIS
Research Octane Number 90 or higher, Leaded Petrol
Oil Grade, Viscosity API SJ or SL, 20W-50
Engine
Engine Proper
• Features of K3-DE Engine
– L4, 1.3-liter, 16-valve, DOHC, leaded gasoline
engine with DIS
Stepper Motor
DIS Type ISC
LLC Plastic type
Intake Manifold
Stainless Steel
Exhaust Manifold
Flexible
Flywheel
Manifold Pressure
Sensor
Engine
Engine Proper
• Features of K3-DE Engine
Air
Bleeder
Serpentine
Drive Belt
Aluminum
Oil Pan
Engine
Engine Proper
• Cylinder Head
– Plastic region bolt are used for cylinder head
SST (09043-50080)
Plastic Region Bolt
Engine
Engine Proper
• Engine Block
– Oil relief valve enclosed in the block to achieve
compact design
To oil
pump
inlet
From oil pump outlet
Engine
Engine Proper
• Piston
– Rings are designed for leaded specifications
Top Ring: “NT” 2nd Ring: “T”
Oil Ring: Red paint at ring end
Engine
Engine Proper
• Crankshaft
– Offset crankshaft to reduced side forced during
maximum pressure
Front Intake
Crank Center
8 mm
Bore Center
Exhaust
Engine
Engine Proper
• Crankshaft
– Offset crankshaft
with offset without offset
with offset without offset
Engine
Engine Proper
• Flywheel
– Flexible flywheel to reduce
vibration during running due to
bending vibration of crankshaft
Engine
Engine Proper
• Flywheel
– Flexible flywheel
Components
Flywheel
Compression
Flexible Plate
Plate
Crankshaft
Engine
Engine Proper
• Flywheel
– Flexible flywheel
Operation
Reduces
vibration
Vibration
Flexible Plate
Flexible Type Normal Type
Engine
Valve Mechanism
• Timing Chain
Chain Drive
Valve Mechanism
Tensioner
Service Plug
Chain Driven Oil Pump
Engine
Valve Mechanism
• Valve and Valve Lifter
– Shim less type valve lifter for weight reduction
– Narrower valve stem to reduce valve resistance
and weight
Shim less type Painted mark,
valve lifter upward
Engine
Cooling System
• General
– LLC is used for engine coolant
– The radiator is made by copper
Air Relief
Valve
Copper
Radiator
Engine
Cooling System
• General
– Air Relief valve is provided for better serviceability
Air Relief
Drain Cock Valve
(Engine Block)
Engine
Fuel System
• General
– Fuel return less system is used to reduce
evaporative emissions
Pulsation
Damper
4 Holes Injectors
Pressure Regulator
Filter
Quick connector on pipes
Pump
Engine
Fuel System
• Fuel Reverse-flow Prevention Valve
– Fuel reverse-flow prevention valve is provided to
fuel inlet to prevent fuel from flowing out
Cut Off
Fuel Valve
Inlet Front
When opened
Fuel Reverse-flow Tank capacity
Prevention Valve is 45 liter
Engine Cut-off Valve
Fuel System
• Cut-off Valve
Check
– Operation Valve
Fuel
Tank
Float
When float level When inside tank
When normal driving
becomes high pressure becomes high
Engine
Fuel System
EFI-T (no. 12)
• Fuel Pump DLC 3
– Hints
1. With EFI-T terminal grounded,
pump will operates for 8
seconds when IG switch is ON
E (no. 4)
(engine is not started)
2. With EFI-T terminal open,
pump will operates for 2
ON
seconds when IG switch is ON
(engine is not started)
Engine
Ignition System
• DIS (Direct Ignition System)
– DIS, provides 2 coils, one for two cylinders
– 2nd and 3rd cylinder, 1st and 4th cylinder
1st and 4th
DENSO NGK
K2OPR-U BKRGE
Gap 0.8 mm 0.8 mm
Width
2nd and 3rd Across 16 mm 16 mm
Flats
Engine
Ignition System
• Inspection
– Ignition Timing
Proper Ignition Timing
(BTDC 6º 2º)
TDC
Timing
Groove
Crankshaft Pulley
Engine
Engine Mounting
• ID Marking
ID Marking
RH R Rear side
Engine
LH L3 Front side
Mount
RR --------
R Mark
Engine Mount RH
Engine
Engine Control System
• Components
Combination Meter
(Vehicle Speed Sensor)
Relay Block
Fuel
Pump
DLC 3
Manifold
Pressure Sensor
Variable
Resistor Engine ECU
Engine
Engine Control System Throttle
• Components Position Sensor
Ignition Coil
Stepper Motor with Igniter
Type ISC
Camshaft
Position
Injector Sensor
Water Temp.
Sensor
Knock
Sensor
Crankshaft
Position
Sensor
Engine
Engine Control System
• Components
Components Outline Quantity
Engine ECU 16 Bit 1
Pressure Sensor D-Type 1
Crank Position Sensor Pick-up coil Type
1
(Rotor Teeth) (36-6)
Knock Sensor Built-in Piezoelectric 1
Throttle Position Sensor Linear Type 1
Injector 4 Holes Type 4
Cam Position Sensor Pick-up coil Type 1
Water Temp. Sensor Thermistor Type 1
Ignition coil DIS 2
Vehicle Speed Sensor Reed Switch Type 1
Engine
Engine Control System
• Crankshaft Position Sensor
– Outputs the crankshaft rotational signal every 10º
to detect engine speed, and the missing teeth are
used to determine cylinder identification
“D” = Front Mark
Signal Rotor
Output
(V)
0
Crankshaft Position Sensor
Cylinder Identification Signal
(No teeth area)
Engine 1. Based on Water Temp.
Sensor
Engine Control System
2. Coefficients of various
• Injection Method corrections
– Synchronous injection 3. Battery Voltage Correction
During starting period
Ignition Signal Fuel Injection
Cyl.
Intake
No.1
Cyl.
Exhaust
No.3
Cyl.
Combustion
No.4
Cyl.
Compression
No.2
Engine 1. Basic Injection Time is
based on intake pressure
Engine Control System and Engine revolution
• Injection Method speed
– Synchronous injection 2. Correction from various
After starting period sensors
Ignition Signal Fuel Injection
Cyl.
Intake
No.1
Cyl.
Exhaust
No.3
Cyl.
Combustion
No.4
Cyl.
Compression
No.2
Engine 1. During change on idle
switch
Engine Control System
2. During change on intake
• Injection Method pressure
– Nonsynchronous 3. During resuming period
injection after fuel cutting
Ignition Signal Fuel Injection
Cyl.
Intake
No.1
Cyl.
Exhaust
No.3
Cyl.
Combustion
No.4
Cyl.
Compression
No.2
Nonsynchronous
Injection
Engine
Engine Control System
• Idle Speed Control
– 2 coil stepper motor ISC is used for high control
accuracy on idle speed
Stepper Motor Type ISC
Engine
Engine Control System
• Idle Speed Control
– Construction of stepper motor
Stepper Motor
Type ISC
Stator Coil A
Stator Coil B
Rotor
(w/ Magnet)
Engine
Engine Control System
• Idle Speed Control
– System Diagram
A
Coil A +V
A’
Coil B +V
B’
Engine 1 2
Extension
3 4
A
Engine Control System Coil A
A’
• Idle Speed Control B
– Operation principle Coil B
B’ : +V
Retraction
Extension
-1- -2- -3- -4-
Coil A N S N N S N S N S S N S
Coil B S N S N S N N S N S N S
Rotor
Retraction
15° / step
Engine
Engine Control System
• Air Conditioner Cut Control
When the following condition is
satisfied, A/C is cut:
•By coolant temperature
– When coolant temperature above
set value (107ﾟC)
When at least one of the conditions is
satisfied, A/C is cut:
• When throttle valve opening degree
exceeds set value by vehicle speed
• When throttle valve opening degree
becomes set value or more
Engine
Engine Control System
• VF Monitor Function
– The VF terminal voltage shows if there is
abnormality found by the diagnosis
DLC3
SST: 09843-18040 EFI-T
VF
E
V VF and E Voltage
•Ignition Switch ON 5V Normal
•Do not depress accelerator pedal
0V Abnormal
Engine
Engine Control System
• Diagnosis Trouble Code
– DTC list which are different
from other TOYOTA DTC
Other
DTC No. Detection Item
TOYOTA DTC
42 22 Water Temperature Sensor Malfunction
18 52 Knock Sensor Circuit Malfunction
14 12 Camshaft Position Sensor Circuit Malfunction
52 42 Vehicle Speed Sensor Circuit Malfunction
71 33 Idle Speed Control System Malfunction
75 18 VVT Sensor Circuit Range/Performance Problem
51 - Switch Signal Circuit Malfunction
44 - A/C Evaporator Temp. Sensor Circuit Malfunction
Engine
Engine Control System
• Fail-safe
DTC No. Detected Item Fail-safe Operation
- Pressure
signal is set to the value determined
by throttle opening angle, engine speed and
Pressure sensor open
31 ISC opening angle
or short circuit
- Fuel will be cut when idle switch is off and
engine rpm exceeds 3500 rpm.
Water temp. signal - The value is set to 79ﾟ C (inside ECU)
42
open or short circuit - Radiator fan will be turned ON
Throttle signal open
41 - Throttle signal is set to 20ﾟ (inside ECU)
or short circuit
Knock sensor open or
18 - Ignition timing is retarded
short circuit
Engine
Engine Control System
• Fail-safe
DTC No. Detected Item Fail-safe Operation
- ISC drive is prohibited
ISC drive signal open - Fuel cut occurs and ignitiontiming is retarded
71
or short circuit according to throttle opening angle and ISC
position at the time of failure
A/F adjuster signal -A/F signal is set to constant value of 2.5 Volt
29
open or short circuit (inside ECU)
Evaporator
temperature sensor
44 open or short circuit -Air Conditioner will be cut
for more than certain
length of time
