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 Prevention Tank capacity is
Valve 45 liter
Engine Cut-off Valve

 Fuel System
• Cut-off Valve
– Operation Check
Valve
Fuel
Tank

Float

When float level When inside tank pressure

When normal driving
becomes high 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 seconds when
ON
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 Position
• Components 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 (Rotor Pick-up coil Type
1
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

corrections
• Injection Method
– 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 and
 Engine Control System Engine revolution speed
• Injection Method 2. Correction from various
– Synchronous injection sensors
 After starting period
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

pressure
• Injection Method
– Nonsynchronous 3. During resuming period after
fuel cutting
injection
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

Coil A +V

A’

Coil B +V

B’
Engine
Extension
1 2 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
ﾟ
value (107 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 TOYOTA
DTC No. Detection Item
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 ISC opening
Pressure sensor open or
31 angle
short circuit
- Fuel will be cut when idle switch is off and engine
rpm exceeds 3500 rpm.

42
ﾟ
Water temp. signal open - The value is set to 79 C (inside ECU)
or short circuit - Radiator fan will be turned ON

41
Throttle signal open or
short circuit
ﾟ
- Throttle signal is set to 20 (inside ECU)

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 or - Fuel cut occurs and ignition timing is retarded
71
short circuit according to throttle opening angle and ISC position
at the time of failure

A/F adjuster signal open -A/F signal is set to constant value of 2.5 Volt (inside
29
or short circuit ECU)

Evaporator temperature
sensor open or short
44 -Air Conditioner will be cut
circuit for more than
certain length of time