NEW FEATURES 3E E ENGINE. 1. Description 12 TERCEL NEW FEATURES

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1 12 TERCEL NEW FEATURES NEW FEATURES 3E E ENGINE 1. Description The 3E E engine is based on the 1.5 liter, 12 valve, OHC 3E engine, but with fuel injection, ignition timing and other engine functions controlled electronically. Electronic control not only increases the engine output and torque but also makes it easier to operate.

2 TERCEL NEW FEATURES Engine Specifications and Performance Curve Engine Item 3E EE 3E No. of Cyls. & Arrangement 4 Cylinder, In Line Valve Mechanism 3 Valves, OHC, Belt Drive Combustion Chamber Wedge Type Manifold Cross flow Displacement cu. in. (cc) 88.9 (1457) Bore x Stroke in. (mm) 2.87 x 3.43 (73 x 87) Compression Ratio 9.3 : 1 Max. Output (SAE NET) rpm rpm Max. Torque (SAE NET) 89 ft rpm 87 ft rpm Fuel Octane Number (R) 91

3 14 TERCEL NEW FEATURES 3. Engine Cylinder Head Due to the adoption of EFI (Electronic Fuel Injection), an Installation Portion has been added to the cylinder head. Otherwise, it is the same as in the 3E engine. Cooling System A pressurized, force circulation cooling system like that in the 3E engine is used. Due to the adoption of EFI, a cold start injector time switch and water temperature sensor are mounted in the water outlet housing. An air valve has been added to the cooling circuit. Graphic

4 TERCEL NEW FEATURES 15 Air Induction System 1) Air Cleaner The same type of axial flow air cleaner element as in the 3E engine is used to make the air cleaner smaller and more lightweight. The air cleaner case is made of resin for reduced weight. The case support is made of rubber, which helps to reduce air intake noise. The air cleaner hose is also made of resin to reduce weight. Bellows shaped rubber is used at the joints of the air cleaner case and throttle body to absorb engine vibrations. 2) Throttle Body In addition to the throttle valve and throttle position sensor, an air valve for fast idle and a dash pot to improve the feeling during deceleration are mounted in the throttle body. The air valve is a wax type valve which operates in accordance with the coolant temperature. It is integrated with the throttle body to simplify the air and coolant piping. An idle up air intake and outlet port is also provided in the air valve. The dash pot includes an integrated VTV (Vacuum Transmitting Valve) and filter for light weight and simplification of components.

5 16 TERCEL NEW FEATURES Construction and Operation Engine coolant is introduced into the air valve from the water inlet pipe. At the same time as the engine coolant is heating the thermo wax, it heats the throttle body to prevent icing of the throttle valve. The air valve control valve opens in accordance to the coolant temperature through the action of thermo wax, thus controlling the volume of air which by passes the throttle valve and is drawn into the cylinders. 3) Intake Manifold The intake air chamber and EGR (Exhaust Gas Recirculation) port are integrated with the intake manifold to simplify the component parts and reduce weight. A stay is added inside the intake manifold to reduce vibration.

6 TERCEL NEW FEATURES TCCS (TOYOTA Electronic Controlled System) General The TCCS for the 3E E engine has the same basic construction and operation as for the 4A FE engine in the current Corolla. However, by the adoption of the fuel pressure control system and the EGR cut off system, the TCCS is matched to the 3E E engine. A comparison of the TCCS control systems in the new 3E E engine and the current 4A FE engine is shown below. However, the 4A FE engine specifications shown here are those for the 1989 Corolla (All Trac/4WD). Engine System EFI (Electronic Fuel Injection) ESA (Electronic Spark Advance) ISC (Idle Speed Control) Idle Up Control Fuel Pressure Control Fuel Pump Control EGR Cut Off Control Diagnosis Fail Safe 3E EE A D type EFI system is used, which indirectly detects intake air volume by the manifold pressure sensor signal. The fuel injection system simultaneously operates all injectors. ( Page 21) Ignition timing is determined by the ECU (Electronic Control Unit) based on signals from various sensors. N.A. Idle up control by VSV (Vacuum Switching Valve) ( Page 22) For hot engine starting, the fuel pressure is increased to improve restartability. ( Page 23) Fuel pump operation is controlled by signals from ECU due to adoption of the manifold pressure sensor. Cuts off EGR according to the engine condition to maintain drivability and engine performance. ( Page 23) When a malfunction occurs, the ECU diagnoses and stores the appropriate diagnostic code. 14 diagnostic items are monitored by the ECU. ( Page 24) When a malfunction occurs, the ECU stops or controls the engine according to the data already stored in memory. ( Page 25) 4A FE ACV regulates air volume by passing throttle valve and controls idling speed. N.A. N.A.

7 18 TERCEL NEW FEATURES System Construction The configuration of the TCCS in the 3E E engine is as follows.

8 TERCEL NEW FEATURES 19 Summary of TCCS Control The following list summarizes the types of sensors, ECU, etc. involved in each system and type of control composing the TCCS of the 3E E engine.

9 20 TERCEL NEW FEATURES TCCS System Diagram

10 TERCEL NEW FEATURES 21 Construction and Operation of Main Components The following list summarizes the types of sensors, ECU, etc. involved in each system and type of control composing the TCCS of the 3E E engine. Components Engine (Model) Type Manifold Pressure Sensor 4A FE (All Trac/4WD Corolla AE95) Throttle Position Sensor 3S FE (FWD Celica ST162) Point Distributor 3S FE (FWD Celica ST162) Two Pick Up Coils Igniter 3S FE (FWD Celica ST162) Separated from Distributor Oxygen Sensor 3S FE (FWD Celica ST162) Without Heater EFI (Electronic Fuel Injection) 1) General The EFI system can be separated into three systems as in the 4A FE engine, the fuel system, the air induction system and the electronic control system. The air induction system is identical to the 4A FE engine, but the fuel system and the electronic control system have been changed slightly to match the 3E E engine. a. Fuel System This is basically the same as that used in the 4A FE engine EFI system. Fuel is pressurized by an electric pump, then flows to the injector through the filter. There is one injector for each cylinder and it injects fuel whenever its solenoid valve opens. The fuel pressure is kept constant at 41.2 lb/in. 2 (2.90 kg/cm 2 ) by the pressure regulator so that the injection volume is controlled by changing the duration of each injection., Whereas the bi directional type fuel injector is used in the 4A FE engine, a single hole type fuel injector like that in the 3VZ FE engine is used in the fuel system in the 3E E engine. b. Air Induction System Intake air from the air cleaner is supplied to the engine through the throttle body, intake manifold and flows to each intake port. The intake manifold pressure is measured by the manifold pressure sensor and its signals are used by the ECU to determine the basic injection duration. Also, there is an air valve for bypassing the throttle valve in order to increase engine idle speed (fast idle) during cold engine running. c. Electronic Control System The ECU controls the injection duration based on data stored in its memory and signals from the sensors. To prevent overrun when the engine is running at high speed, the fuel is cut off at a speed of 6800 rpm. Except for this, the system is the same as in the 4A FE engine.

11 22 TERCEL NEW FEATURES 2) Fuel Injector The fuel injectors are high resistance type fuel injectors which have solenoid resistors mounted outside as in the 4A FE engine. However, in keeping with the layout of the intake valve, single hole type injection nozzles like those in the 3VZ E engine are used. The injection volume for one injector is 8.85 cu. in./mm (145 cc/min.). Idle Up Control A VSV (Vacuum Switching Valve) like that in the Corolla 4A GE engine is used in the 3E E engine to provide a by pass circuit around the throttle valve. The ECU turns the VSV on when the idle speed drops to 600 rpm or lower due to an increase in the electrical load, etc. in order to increase the idle speed. The VSV is switched off if the idle speed goes above 950 rpm during idle up. In this way, idle speed is kept within the 600 rpm to 950 rpm range. In addition, the VSV is switched on during engine cranking and immediately after the engine is started to improve startability and stability immediately after the engine is started. The VSV is also switched on while the engine is idling if the coolant temperature is below 158 F (70 C) to maintain control by means of the air valve and to maintain a fast idle speed. The VSV is switched off regardless of the engine s condition by connecting the T and E 1 terminals of the check connector in order to perform engine adjustments.

12 TERCEL NEW FEATURES 23 Fuel Pressure Control This system is the same as that used in the 4A GE engine for the Corolla. It includes a VSV in the vacuum line from the intake manifold to the pressure regulator to control the fuel pressure in accordance to whether or not intake manifold vacuum or atmospheric pressure is acting on the diaphragm chamber of the pressure regulator. When the coolant temperature is above 158 F (70 C) while the engine is being cranked with the IDL contacts closed (when the accelerator pedal is not depressed), the ECU turns on the VSV and increases the fuel pressure to prevent the fuel percolation as well as to maintain engine restartability and idling stability. The increase in fuel pressure is continued for 90 seconds after the engine starts or until the IDL contacts open. EGR Cut Off Control This system is the same as that in the 3VZ E engine of the Truck/4Runner. It includes a VSV installed in the vacuum line from the EGR vacuum modulator to the EGR valve. The ECU cuts off the EGR by switching this VSV on and causing atmospheric pressure to act on the diaphragm chamber. The ECU cuts off the EGR under the following conditions and for the following purposes. Condition Coolant temperature is below 122 F (50 C) or engine load is below predetermined level. IDL contacts are closed (accelerator pedal is not depressed). Engine speed is higher than 4000 rpm or PSW contacts are closed (throttle valve opening angle is above 40 degrees). Purpose To maintain drivability To maintain idling stability To maintain engine performance

13 24 TERCEL NEW FEATURES Self Diagnosis The diagnostic system in the new 3E E engine monitors fourteen conditions as shown in the chart below, but the diagnostic items have been changed for the 3E E engine. Whenever a malfunction is detected which is indicated by in the CHECK ENGINE lamp column, the ECU turns on the CHECK ENGINE lamp to alert the driver that it has detected a malfunction in the engine. Code No. 12 RPM Signal 13 RPM Signal Ignition Signal Item Diagnosis Trouble Area Oxygen Sensor Signal Water Temp. Sensor Signal Intake Air Temp. Sensor Signal Air Fuel Ratio Lean Malfunction Air Fuel Ratio Rich Malfunction No Ne signal to ECU within 2 seconds after the engine is cranked. No Ne signal to ECU when the engine speed is above 1000 rpm. No IGf signal to ECU 4 times in succession. During air fuel ratio feedback correction, output voltage of oxygen sensor remains between 0.35V and 0.7V continuously for a certain period. Open or short circuit in water temp. sensor signal (THW). Open or short circuit in intake air temp. sensor signal (THA). When air fuel ratio feedback correction value or adaptive control value continues at the upper (lean) or lower (rich) limit for a certain period of time or adaptive control value is not renewed for a certain period of time. When marked variation is detected in engine revolution for each cylinder during idle switch on and feedback condition. Open or short circuit in oxygen sensor signal (Ox). Distributor circuit Distributor Starter signal circuit Distributor circuit Distributor Igniter circuit Igniter Oxygen sensor circuit Oxygen sensor Water temp. sensor circuit Water temp. sensor Intake air temp. sensor circuit Intake air temp. sensor Injector circuit Injector Fuel line pressure Oxygen sensor circuit Oxygen sensor Manifold pressure sensor Water temp. sensor Injector circuit Injector Fuel line pressure Oxygen sensor circuit Oxygen sensor Cold start injector circuit Cold start injector Manifold pressure sensor Water temp. sensor CHECK ENGINE Lamp

14 TERCEL NEW FEATURES 25 Code No Item Diagnosis Trouble Area Manifold Pressure Sensor Signal Throttle Position Sensor Signal Vehicle Speed Sensor Signal 43 Starter Signal 71 EGR System Malfunction Open or short circuit in manifold pressure sensor signal (PIM). The IDL and PSW signals are output simultaneously for several seconds. Open or short circuit in vehicle speed sensor signal. No STA signal to ECU until engine speed reaches 800 rpm with vehicle not moving. EGR gas temp. is below a predetermined level during EGR operation. Open circuit in EGR gas temp. sensor signal (THG). Manifold pressure sensor circuit Manifold pressure sensor Throttle position sensor circuit Throttle position sensor Vehicle speed sensor circuit Vehicle speed sensor Starter signal circuit Ignition switch EGR system components EGR gas temp. sensor circuit EGR gas temp. sensor CHECK ENGINE Lamp OFF OFF 51 Switch Signal No IDL signal or No NSW signal or A/C signal to ECU, with the check terminals T and E 1 connected. A/C amplifier A/C switch circuit Neutral start switch circuit Neutral start switch Accelerator pedal and cable Throttle position sensor circuit Throttle position sensor OFF NOTE: If two or more malfunctions are present at the same time, the lowest numbered diagnostic code will be displayed first. All detected diagnostic codes, except 51, will be retained in memory by the ECU from the time of detection until cancelled out. Once the malfunction is corrected, the CHECK ENGINE warning lamp will go out but the diagnostic code(s) will remain stored in the ECU memory (except for code 51). After the malfunction is corrected, the diagnostic code is cleared by removing the EFI fuse for more than 10 seconds with the ignition switch off. Fail Safe Back Up Function If Ignition signals are not output due to a malfunction occurring in the program of the ECU or due to the signal from the manifold pressure sensor being abnormal, the ECU fixes the fuel injection and ignition timings at specified values. As in the current 4A FE engine, fuel injection is divided into 3 steps by the starting signal (STA) and the throttle position signal (IDL). Whereas in the current 4A FE engine the ignition timing is fixed at 10 BTDC, the ignition timing in the 3E E engine is fixed at 5 BTDC. NOTE: If the T and E 1 terminals of the check connector are connected for engine adjustment, etc., the ignition timing is fixed at 10 BTDC as in the current engine. When the engine is started, ignition timing is fixed at 5 BTDC, the same as for the back up function.

15 26 TERCEL NEW FEATURES 5. Emission Control System System Purpose System Abbreviation Purpose Positive crankcase ventilation Evaporative emission control Exhaust gas recirculation Three way catalyst Electronic fuel injection PCV EVAP EGR TWC EFI Reduces blow by gas (HC) Reduces evaporative HC Reduces NOx Reduces HC, CO and NOx Regulates all engine conditions for reduction of exhaust emission Component Layout and Schematic Drawing