6

AVENSIS NEW FEATURES

NEW FEATURES
J1AD-FTV ENGINE (WITH DPF CATALYTIC CONVERTER)
1. Description
A DPF (Diesel Particulate Filter) catalytic converter has been added to the 1AD-FTV engine to improve its
exhaust gas cleaning performance.
Along with the provision of the DPF catalytic converter, an EGR bypass switching valve, exhaust fuel
addition injector, and catalyst support control have been added.
"

Engine Specification A

Model

With DPF

Without DPF

4-cylinder, In-line

16-valve DOHC,
Chain and Gear Drive

Direction Injection Type

Cross-flow

Common-rail Type

1998 (121.9)

86.0 x 86.0 (3.39 x 3.39)

Compression Ratio

16.8 : 1

Max. Output (EEC)

93 kW @ 3600 rpm

Max. Torque (EEC)

300 N.m @ 1800 2400 rpm

300 N.m @ 2000 2800 rpm

Open

2_ BTDC

Close

31_ ABDC

Open

51_ BBDC

Close

2_ ATDC

ACEA B1, C2 (Prefer)*1

G-DLD1 or ACEA B1,

API CF-4 or CF

1342

Fuel Cetane Number

48 or more

Emission Regulation

IV*2

No. of Cyls. & Arrangement

Valve Mechanism
Combustion Chamber
Manifolds
Fuel System
Displacement

cm3 (cu. in.)

Bore x Stroke

mm (in.)

Intake
Valve
Timing
Exhaust
Oil Grade
Firing Order

Engine Service Mass

(Reference)

EURO
kg (lb)

152 (335)

EURO IV
147 (324)

*1:When you use non-recommended oil such as API CF grade, you may need extra maintenance for DPF.
Recommended oil viscosity: 5W-30
*2: PM: 80% less than EURO IV regulations

AVENSIS NEW FEATURES

"

Valve Timing A
: IN Valve Opening Angle
: EX Valve Opening Angle
TDC
2_ 2_

51_

31_
BDC

288EG03Y

"

Performance Curve A
120
110
100

400
350
Torque
(N.m)

300

90
80

250

70

200

60

150
100

50
40
30
20
10
0
1000 2000

3000 4000

5000

Engine Speed (rpm)

02JEG22Y

Output
(kW)

AVENSIS NEW FEATURES

2. Features of 1AD-FTV Engine

The 1AD-FTV engine has achieved the following performance through the use of the items listed below.
(1) High performance and reliability
(2) Low noise and vibration
(3) Lightweight and compact design
(4) Good serviceability
(5) Clean emission and fuel economy
Item

Engine
Proper

Valve
V
l
Mechanism

Cooling
System

Intake and
Exhaust
System

With
DPF

Without
DPF

A cylinder head and cylinder block made of

aluminum alloy are used.
Piston provided with combustion chamber
is used in conjunction with the adoption of
direct injection.

Hydraulic lash adjuster is used.

f
f
f

A timing chain and chain tensioner are used.

Roller rocker arms are used.

Lubrication
System

(1) (2) (3) (4) (5)

An oil filter with a replaceable element is

used.
The water-cooled type oil cooler is used.

f
f

TOYOTA Genuine SLLC (Super Long Life

Coolant) is used.

A rotary solenoid type diesel throttle control

motor is used in the throttle body.

A linear solenoid type EGR valve is used.

A water-cooled type EGR cooler is used.

A water-cooled type EGR cooler with a

bypass is used.

The variable nozzle vane type turbocharger

is used.

The exhaust manifold converter uses

oxidation catalyst and DPF catalyst.

Fuel
System

A common-rail type fuel injection system is

used.

Solenoid type injectors on which

compensation value and QR code are
printed are used.

An exhaust fuel addition injector is used.

Charging
g g
System

A segment conductor type alternator is

used.
An alternator pulley with a one-way clutch
is used.

f
f

(Continued)

AVENSIS NEW FEATURES

Item
Serpentine
Belt Drive
System

A serpentine belt drive system is used.

A pilot injection control system is used.

Engine
Control
System

(1) (2) (3) (4) (5)

f

An oil maintenance management system is

used.

With
DPF

Without
DPF

A charging control system is used.

A catalyst support control is used.

3. Engine Proper
Cylinder Head
A hole for installing the exhaust fuel addition injector is located on the No. 4 exhaust port of the cylinder
head.
Hole for Installing Exhaust Fuel
Addition Injector

Front

View from A
Cylinder Head
288EG73Y

10

AVENSIS NEW FEATURES

4. Intake and Exhaust System

General
D A bypass path with a switching valve is added to the EGR cooler.
D An oxidation catalyst and DPF catalyst are used in the exhaust manifold converter.
EGR Cooler
A bypass with an EGR cooler bypass switching valve is added to the EGR cooler.
D If EGR gas is cooled down in the EGR cooler with light engine load, compression air temperature
decreases. To prevent this, the EGR gas passage is switched by the EGR cooler bypass switching valve.
Water IN

Exhaust Gas IN
Exhaust Gas IN
Bypass Switching Valve
Water OUT

Water IN
A

Exhaust Gas
OUT
A
Bypass Path

Exhaust Gas

Outlet for
Cooler Side Gas

Water

Outlet for
Bypass Side Gas

Exhaust Gas OUT

EGR Cooler

A A Cross Section

Water OUT

02JEG23Y

Exhaust Manifold Converter

D The exhaust manifold converter consists of the oxidation catalyst and DPF catalyst.
D The DPF catalyst purifies the PM (Particulate Matter), HC, CO.

Exhaust Gas
PM
Oxidation Catalyst

Filter

DPF Catalyst

02JEG08Y

11

AVENSIS NEW FEATURES

5. Fuel System
General
D The fuel outlet for the exhaust fuel addition injector is added to the supply pump.
D The exhaust fuel addition injector is added for catalyst support control.

Supply Pump

Fuel Tank

Injector
EDU

Quick Connectors
Common-rail
D Fuel Pressure Sensor

Fuel Filter
Exhaust Fuel Addition Injector*
02JEG17Y

*: Only for DPF Models

12

AVENSIS NEW FEATURES

Common-rail System
1) General
In this system, the high pressurized fuel that is supplied by the supply pump is stored in the common-rail,
and the engine ECU sends signals to the injectors via the EDU (Electronic Driver Unit) in order to control
the injection timing and injection volume.
"

System Diagram A
Fuel Pressure Sensor

Pressure Limiter
Common-rail

Fuel Temperature Sensor

Supply
Pump
Exhaust Fuel
Addition Injector*

Fuel
Filter

Injector

EDU

Fuel Tank

Engine
ECU
02JEG11Y

*: Only for DPF Models

2) Supply Pump
The fuel outlet for the exhaust fuel addition injector is added.
Fuel Outlet

288EG101Y

13

AVENSIS NEW FEATURES

3) Exhaust Fuel Addition Injector
D An exhaust fuel addition injector is
installed on the No. 4 exhaust port of the
cylinder head. This injector supplies
additional fuel into the No. 4 exhaust
port, and maintains the proper catalyst
temperature for the purpose of PM
(Particulate Matter) recovery.
D An exhaust fuel addition injector consists
of a needle valve body, needle valve, and
solenoid valve.

Solenoid Valve

Needle Valve

Needle Valve Body

288EG89Y

14

AVENSIS NEW FEATURES

6. Engine Control System

General
The engine control system for the 1AD-FTV engine has following systems.
Outline

With
DPF

Without
DPF

j
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
j
Timing Control

Based on the signals received from the sensors, the

engine ECU determines the fuel injection timing in
accordance with the engine condition.

Fuel Pressure
Control

Based on the signals received from the sensors, the

engine ECU controls fuel pressure using the SCV
according to engine conditions.

Pilot Injection
j
Control

Based on the signals received from the various sensors,

the engine
ECU determines ppilot injection
volume,
g
j
timing, and interval (between pilot injection and main
injection) in accordance with the engine condition.

Catalyst
y Support
pp
Control
(See page 24)

Based on the signals

g
received from the sensors,, the
engine ECU controls exhaust fuel addition injector to
purify PM.

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 maintain the target idle speed.

Glow Plug Control

Controls the length of time when the current is applied

to the glow plugs, in accordance with water temperature.

Based on the signals received from the sensors, the

engine ECU determines the EGR volume via EGR valve
and diesel throttle control valve in accordance with the
engine condition.

Based on the signals received from the sensors, the

engine ECU determines the EGR volume via EGR valve,
EGR cooler bypass switching valve and diesel throttle
control valve in accordance with the engine condition.

Turbo Pressure
Control

Based on the signals received from the sensors, the

E VRV in
engine ECU controls the actuator via E-VRV
accordance with the engine condition.

Intake Throttle
Control

D Based on the signals received from the various

sensors, the engine ECU determines throttle position
condition
in accordance with engine condition.
D Fully closes the diesel throttle control valve in order
to reduce the vibration when the engine is stopped.

System

EGR Control
(See page 25)

(Continued)

15

AVENSIS NEW FEATURES

Outline

With
DPF

Without
DPF

Charging Control

The engine ECU regulates the charging voltage of the

alternator in accordance with the driving conditions and
the charging state of the battery

Air-fuel Ratio Sensor

Heater Control

Maintains the temperature of the air-fuel ratio sensor at

an appropriate level to increase accuracy of detection of
the oxygen concentration in the exhaust gas.

Air Conditioner
Cut-off Control

By controlling the air conditioner compressor ON or

OFF in accordance with the engine condition, drivability
is maintained.

Engine
Immobilizer

Prohibits fuel injection if an attempt is made to start the

engine with an invalid ignition key.

Oil Maintenance
Management
System

When the engine ECU determines engine oil

deterioration, the engine oil change reminder light turns
ON to inform the driver.

Diagnosis
(See page 26)

When the engine ECU detects a malfunction, the engine

ECU diagnoses and memorizes the failed section.

Fail-safe
(See page 26)

When the engine ECU detects a malfunction, the engine

ECU stops or controls the engine according to the data
already stored in the memory.

System

16

AVENSIS NEW FEATURES

Construction
The configuration of the engine control system is as shown in the following chart.
SENSORS
AIR FLOW METER
ATMOSPHERIC
TEMPERATURE SENSOR
INTAKE AIR TEMPERATURE
SENSOR

ACTUATORS
#1

VG

#3

THA

#4
INJF

THIA

WATER TEMPERATURE SENSOR THW

CRANKSHAFT POSITION
SENSOR
CAMSHAFT POSITION SENSOR

DIESEL THROTTLE POSITION

SENSOR

VLU

FUEL TEMPERATURE SENSOR

THF

EGR VALVE POSITION SENSOR

DIFFERENTIAL PRESSURE
SENSOR*

PCR1

BATTERY CURRENT SENSOR

PCV

No. 3 INJECTOR
No. 4 INJECTOR

EDU RELAY

EXHAUST FUEL
ADDITION INJECTOR*

SUCTION CONTROL VALVE

INTAKE THROTTLE CONTROL

ENGINE
ECU

LUSL

DIESEL THROTTLE
CONTROL MOTOR

GLOW PLUG CONTROL

EGLS
GREL

GLOW PLUG RELAY

PEX

EXHAUST GAS TEMPERATURE THCO

SENSOR (LOWER SIDE)*

BATTERY TEMPERATURE
SENSOR

EDU

PIM

EXHAUST GAS TEMPERATURE THCI

SENSOR (UP SIDE)*

ALTERNATOR

FIV

G
VPA
VPA2

TURBO PRESSURE SENSOR

IREL

No. 2 INJECTOR

NE

ACCELERATOR PEDAL
POSITION SENSOR

FUEL PRESSURE SENSOR

No. 1 INJECTOR

#2

EGR CONTROL
EGRS
ECBV

EGR VALVE
VSV (FOR EGR COOLER
BYPASS SWITCHING VALVE)*

ALT
RL
THB
IB

TURBOCHARGER CONTROL
VN

E-VRV

(Continued)
*: Only for DPF Models

02JEG09Y

17

AVENSIS NEW FEATURES

CLUTCH SWITCH

CRUISE CONTROL SWITCH

SKID CONTROL ECU

AIR-FUEL RATIO SENSOR*
STOP LIGHT SWITCH

CLSW

CHARGING CONTROL

CCS
RLO
TRC

AF2

AIR-FUEL RATIO SENSOR

HEATER CONTROL*

STP
HAF2

POWER STEERING OIL

PRESSURE SENSOR
TAIL LAMP RELAY

PSP

ENGINE
ECU

COOLING FAN CONTROL

MPX2
FAN

IGNITION SWITCH
D Starter Signal
D Ignition Signal
COMBINATION METER

MREL
SPD

MAIN RELAY
+B

IMI
IMO
SIL, TC

DLC3

COOLING FAN RELAY

STA
IGSW

D Vehicle Speed Signal

TRANSPONDER KEY ECU

AIR-FUEL RATIO
SENSOR HEATER

ELS

PTC

AIR CONDITIONER ECU

ALTERNATOR
(IC REGULATOR)

WFSE

MPX1
W

COMBINATION METER
CHECK ENGINE
WARNING LIGHT

BATT

BATTERY
02JEG10Y

: BEAN

*: Only for DPF Models

18

AVENSIS NEW FEATURES

Engine Control System Diagram
Combination Meter
D Vehicle Speed Signal
D Check Engine Warning Light
D Glow Indicator Light
D Engine Oil Change Reminder Light

Accelerator Pedal
Position Sensor

Fuel Temperature
Sensor

BEAN

BEAN
Air Conditioner
ECU

Supply Pump
Alternator

Tail Light Relay

Cooling Fan Relay

Stop Light Relay

Starter Relay
Ignition
Switch

Fuel Pressure Sensor

Main Relay
Battery Current Sensor
Battery Temperature Sensor

Battery

SCV

Engine
ECU

Common-rail

DLC3

Power Steering Oil Pressure Sensor

EDU Relay

EDU

Intake Air
Temperature
Sensor
Atmospheric Temperature
Sensor

Diesel Throttle
Control Motor

EGR Valve
Air Flow Meter

VSV (For EGR Cooler

Bypass Switching Valve)*

Injector
Actuator

Camshaft
Position
Sensor

E-VRV
(For Turbocharger Control)
Exhaust Temperature Sensor
(Up Side)*
Exhaust Temperature Sensor
(Lower Side)*

Exhaust Fuel
Addition
Injector*
Differential
Pressure Sensor*

Throttle
Position
Sensor

Turbo Pressure
Sensor

Glow
Plug
Water
Temperature
Sensor

Glow
Relay

Crankshaft Position
Sensor
Air-fuel Ratio Sensor*

02JEG13Y

*: Only for DPF Models

19

AVENSIS NEW FEATURES

Layout of Main Components
Air Flow Meter
Battery Current Sensor
Differential
Pressure Sensor*
EDU

Intake Air Temperature

Sensor

Glow Plug Indicator

Engine Oil Change

Reminder Light

Air-fuel Ratio Sensor*

Battery Temperature Sensor

Check Engine
Warning Light

Engine ECU

DLC3

Accelerator Pedal
Position Sensor

02JEG19Y

*: Only for DPF Models

20

AVENSIS NEW FEATURES

Injector

Suction Control Valve

Glow Plug

Fuel Pressure Sensor

Fuel Temperature
Sensor
Exhaust Fuel
Addition Injector*
Water Temperature
Sensor

Turbo Pressure
Sensor

EGR Valve
Diesel Throttle Position Sensor
E-VRV
(For Turbocharger Control)

VSV (For EGR Cooler

Bypass Switching Valve)

Camshaft Position Sensor

Exhaust Temperature
Sensor (Up Side)*

Exhaust Temperature
Sensor (Lower Side)*
Crankshaft
Position Sensor
*: Only for DPF Models

02JEG20Y

21

AVENSIS NEW FEATURES

Main Component of Engine Control System
1) General
The main components of the 1AD-FTV engine control system are as follows:
Components
Engine ECU
EDU
Air Flow Meter
Crankshaft Position Sensor (Rotor Teeth)
Camshaft Position Sensor (Rotor Teeth)
Fuel Pressure Sensor
Accelerator Pedal Position Sensor
Diesel Throttle Position Sensor
Differential Pressure Sensor*
Exhaust Gas Temperature Sensor*

Up Side
Lower Side

Air-fuel Ratio Sensor*

Outline
Quantity
32-bit CPU
1
Including a built-in DC-DC converter
1
Hot-wire Type
1
Pick-up Coil Type (36 2)
1
Pick-up Coil Type (1)
1
Semiconductor Strain Gauge Type
1
(Two Circuits Type)
Linear (Non-contact) Type
1
Linear (Non-contact) Type
1
Semiconductor Strain Gauge Type
1
Thermistor Type

1 each

Type with heater (Planar Type)

*: Only for DPF Models

2) Differential Pressure Sensor
D The differential pressure sensor measures the pressure differences between front and back of the DPF
catalyst with PM in order to detect the clogging.
D The sensor is mounted on the cowl, where the effects of vibration are minimal. The DPF catalyst and
the sensor are connected with pipes and hoses.
Differential Pressure Sensor

02JEG25Y

(V)
4.65

Voltage

100
Pressure

(kPa)
02JEG24Y

02JEG26Y

22

AVENSIS NEW FEATURES

3) Exhaust Gas Temperature Sensor
The exhaust gas temperature sensor, which is a thermistor type, is installed in front and back of the DPF
catalyst, in order to detect the temperature of the catalyst.

106
105
Electric
Resistance 104
Value
()
103
102

100 200 300 400 500 600 700 800 900

Exhaust Gas Temperature (_C)

258AE40
258AE41

4) Air-fuel Ratio Sensor

a. General
D The planar type air-fuel ratio sensor is used.
D The planar type air-fuel ratio sensor uses alumina, which excels in heat conductivity and insulation,
to integrate a sensor element with a heater, thus improving the warm-up performance of the sensor.
D This sensor is based on a sensor that is developed for gasoline engines. Its cover is changed for diesel
engine applications in order to eliminate the influences of the sensor temperature and the PM. This
sensor, which is mounted after the DPF catalyst, detects the air-fuel ratio after the gases is reduced.

Alumina
Dilation Layer
Atmosphere
Alumina
Heater
Platinum
Electrode
Sensor Element (Zirconia)

288EG86Y

23

AVENSIS NEW FEATURES

b. Characteristics

The air-fuel ratio sensor and the heated oxygen sensor differ in output characteristics.
The air-fuel ratio sensor data is approximately proportionate to the existing air-fuel ratio. The air-fuel
ratio sensor converts the oxygen density to the current and sends it to the engine ECU.
As a result, the detection precision of the air-fuel ratio has been improved. The air-fuel ratio sensor data
is read out by an intelligent tester II.

4.2

(V)

Air-fuel Ratio Sensor Data

Displayed on Intelligent
Tester II

2.2
11 (Rich)

14.7
Air-fuel Ratio

19 (Lean)
258AE59

24

AVENSIS NEW FEATURES

Catalyst Support Control
1) General
The engine ECU judges manifold converter condition based on signals from the air flow meter, water
temperature sensor, two exhaust gas temperature sensors, differential pressure sensor, and air-fuel ratio
sensor to control the injectors and exhaust fuel addition injector for catalyst support control.
D The catalyst support control consists of the PM reduction control.
Injector
Exhaust Fuel Addition Injector

Water Temperature
Sensor

Air Flow Meter

Engine ECU
Exhaust Gas
Temperature
Sensors

Air-fuel Ratio
Sensor
Differential Pressure Sensor

288EG67C

2) PM Reduction Control
If the DPF catalyst temperature becomes low, catalyst performance decreases, resulting in an increase
of the amount of PM stuck in the filter substrate. When the engine ECU detects clogs in the filter substrate
by calculating the accumulated volume of PM discharged by engine, it operates the injectors and exhaust
fuel addition injector for PM reduction.
D At the same time, filter substrate temperature becomes high and PM reacts with active oxygen and
changes into CO2 for purification.
D Fuel efficiency drops during this control.
Service Tip
D When replacing the exhaust manifold converter with a new one, it is necessary to perform
initialization of the DPF catalyst deteriorate data history in the engine ECU by using the
intelligent tester II.
D When replacing the engine ECU with a new one, it is necessary to read DPF catalyst deteriorate
data history from the installed engine ECU and then transfer that data history to the new engine
ECU by using the intelligent tester II. When the DPF catalyst deteriorate data history is not
transferred, DTC (Diagnostic Trouble Code) P1601 is stored in the engine ECU, and the check
engine warning light comes on.
D When replacing both the exhaust manifold converter and the engine ECU, it is necessary to perform
initialization of the DPF catalyst deteriorate data history in the engine ECU using the intelligent
tester II. When DPF catalyst deteriorate history initialization is not performed, DTC (Diagnostic
Trouble Code) P1601 is stored in the engine ECU and the check engine warning light comes on.
For details, refer to the Avensis Repair Manual Supplement (Pub. No. RM02J1E).

25

AVENSIS NEW FEATURES

EGR Control

By sensing the engine driving conditions, the engine ECU operates the EGR valve, diesel throttle control
motor and VSV (for EGR cooler bypass switching valve) and regulates the amount of EGR gas.

Accelerator Pedal
Position Sensor
Crankshaft Position
Sensor
EGR Valve

Air Flow Meter

Engine
ECU

Water Temperature Sensor

Atmospheric Temperature
Sensor

EGR Cooler Bypass

Switching Valve

Turbo Pressure Sensor

EGR Cooler
To Turbocharger

Engine
Exhaust Gas

288EG103C

26

AVENSIS NEW FEATURES

Diagnosis
D The diagnosis uses the EURO-OBD (Europe On-Board Diagnosis) that complies with European
regulations.
D When the engine ECU detects a malfunction, the engine ECU makes a DTCs (Diagnostic Trouble Codes)
and memorizes the failed section. Furthermore, the check engine warning light in the combination meter
illuminates to inform the driver.
D The engine ECU will also store the DTCs (Diagnostic Trouble Codes) of the malfunctions. The DTC can
be accessed by using the intelligent tester II.
D For details, refer to the Avensis Repair Manual Supplement (Pub. No. RM02J1E).
Service Tip
To clear the DTC that is stored in the engine ECU, use an intelligent tester II, disconnect the battery
terminal or remove the EFI fuse for 1 minute or longer.

Fail-safe
When a malfunction is detected by any of the sensors, there is a possibility of an engine or other malfunction
occurring if the engine ECU were to continue to control the engine control system in the normal way. To
prevent such a problem, the fail-safe function of the engine ECU either relies on the data stored in memory
to allow the engine control system to continue operating, or stops the engine if a hazard is anticipated. For
details, refer to the Avensis Repair Manual Supplement (Pub. No. RM02J1E).