Toyota 1VD-FTV (4.5L V8) Diesel Engine Technical Training Manual

EG ENGINE — 1VD-FTV ENGINE EG-133 1VD-FTV ENGINE J DESCRIPTION The 1VD-FTV engine is newly provided. The 1VD-FTV TOYOTA D-4D (Direct injection 4 stroke common-rail Diesel engine) is V8 4.5 liter, 32-valve DOHC, turbocharged diesel engine with intercooler. This engine uses direct injection system and common-rail system to realize high performance, clean emission, low noise and low vibration. 081EG04Y 081EG05Y

ENGINE — 1VD-FTV ENGINE EG-134 " Engine Specifications A No. of Cyls. & Arrangement 8-Cylinder, V Type Valve Mechanism 32-valve, DOHC, Chain & Gear Drive Combustion Chamber Direct Injection Type Manifolds Cross-flow Fuel System Common-rail Type Displacement cm 3 (cu. in.) 4461 (272.2) Bore  Stroke mm (in.) 86.0  96.0 (3.39  3.78) Compression Ratio 16.8 : 1 Europe 210 kW @ 3600 rpm Max. Output Australia and Europe (Models with pre-cleaner) 195 kW @ 3400 rpm G.C.C. Countries and A/T 173 kW @ 3200 rpm [ECE] G.C.C. Countries and General Countries M/T 162 kW @ 3600 rpm Europe 650 N·m @ 1600 to 2800 rpm Max. Torque Australia and Europe (Models with pre-cleaner) 650 N·m @ 1600 to 2600 rpm G.C.C. Countries and A/T 615 N·m @ 1800 to 2200 rpm [ECE] G.C.C. Countries and General Countries M/T 430 N·m @ 1200 to 3600 rpm Intake Open 2_ BTDC Valve Intake Close 17_ ABDC V alve Timing Exhaust Open 51_ BBDC Exhaust Close 2_ ATDC Firing Order 1-2-7-3-4-5-6-8 Oil Grade Europe ACEA B1, API CF-4 or CF Oil Grade Except Europe G-DLD-1, API CF-4 or CF Fuel Cetane Number Europe 48 or higher Fuel Cetane Number Except Europe 50 (Cetane Index 45) or higher Europe EURO IV Europe EURO III* 1 Australia EURO IV Emission Regulation G.C.C. Countries  EURO III* 2 General Countries EURO II* 3  i S i * 4 Models with A/T 325 (717) Engine Service Mass* 4 (Reference) kg (lb) Models with EGR M/T 340 (750) (Reference) kg (lb) Models without A/T 320 (705) Models without EGR M/T 334 (736) * 1 : Russian package models * 2 : Package models for South Africa, Argentina and Papua New Guinea * 3 : Package models for Philippines and Vietnam * 4 : The figure shown is the weight of the part without coolant and oil.

EG ENGINE — 1VD-FTV ENGINE EG-135 " Valve Timing A : Intake Valve Opening Angle : Exhaust Valve Opening Angle TDC 2_ 2_ 17_ 51_ BDC 058EG01Y

ENGINE — 1VD-FTV ENGINE EG-136 " Performance Curve A 240 Output (kW) Torque (N·m) 220 200 180 160 140 120 100 80 60 40 650 600 550 500 450 400 350 1000 2000 3000 4000 Engine Speed (rpm) 081EG46Y Europe 240 Output (kW) Torque (N·m) 220 200 180 160 140 120 100 80 60 40 650 600 550 500 450 400 350 1000 2000 3000 4000 Engine Speed (rpm) 081EG47Y Australia and Europe (Models with pre-cleaner) : A/T : M/T 240 Torque (N·m) 220 200 180 160 140 120 100 80 60 40 650 600 550 500 450 400 350 1000 2000 3000 4000 Engine Speed (rpm) 081EG48Y G.C.C. Countries and General Countries Output (kW)

EG ENGINE — 1VD-FTV ENGINE EG-137 J FEATURES OF 1VD-FTV ENGINE The 1VD-FTV engine has been able to achieve the following performance through the adoption 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 (1) (2) (3) (4) (5) Cylinder head cover is made of plastic and cylinder head is made of aluminum alloy. f f A cylinder block made of compact graphite iron is used. f f Engine Piston provided in combustion chamber is used in conjunction with the adoption of direct injection. f f Engine Proper The piston skirt is coated with resin. f f The passage for the EGR system is provided in the cylinder head. (Only on models with EGR) f f Crankshaft pulley uses an inertial weight. f A No.1 oil pan sub-assembly made of aluminum alloy is used. f l A camshaft is driven by a timing chain and gear. f f f Valve Mechanism Hydraulic lash adjusters are used. f f f Mechanism Roller rocker arms are used. f f f bi i An oil filter with a replaceable element is used. f Lubrication System A water-cooled type engine oil cooler is used. f System A scavenging pump is used. f Cooling System TOYOTA Genuine SLLC (Super Long Life Coolant) is used as the engine coolant. f The rotary solenoid type diesel throttle motor and a non-contact throttle position sensor are used in the diesel throttle body. f A variable nozzle vane type turbocharger driven by a DC motor is used in each bank. f f f Intake and An air-cooled type intercooler is used. f f Intake and Exhaust System The linear solenoid type EGR valve is used. (Only on models with EGR) f A water-cooled type EGR cooler is used. (Only on models with EGR) f Oxidation catalytic converter is used. (Only on models complying with the emission regulations*) f (Continued)

ENGINE — 1VD-FTV ENGINE EG-138 Item (1) (2) (3) (4) (5) 3-plunger type fuel supply pump is used. f f A common-rail type fuel injection system is used. f f f Solenoid type fuel injectors on which compensation value and QR (Quick Response) code are printed are used. f f f Fuel System A fuel filter, in which the fuel filter element alone can be replaced, is used. f A fuel filter warning switch that detects the clogging of the fuel filter is used. f f Water-cooled and air-cooled type fuel coolers are used. f f Charging System Segment conductor type generator is used. f Engine Mount The electrical hydraulic type engine mountings are used. f Serpentine Belt Drive System A serpentine belt drive system is used. f f A pilot injection control is used. f f f Engine Control A fuel pump control, which has the fuel transfer function, is used. (Only on models with dual fuel tank) f Engine Control System The cranking hold function is used. f An oil maintenance management system is used. (Only on European models complying with EURO IV) f *: Except automatic transmission models complying with EURO II

ENGINE — 1VD-FTV ENGINE EG-174 J CHARGING SYSTEM 1. General D A compact and lightweight segment conductor type generator is used on all models. D A SC6 type generator is provided on European models with the towing package. The cross sectional area of the segment conductors on a stator in this generator has been increased, which reduces the electrical resistance of the stator, generates high power output, and achieves a higher efficiency. This type uses an aluminum die-casting rectifier unit and also provides fins on the rectifier to improve heat dissipation. Segment Conductor Stator Portion Generator Cross Section : SC6 Type : Conventional Type Rectifier Portion Fin 081EG66TE " Specifications A Type SC1 SC2 SC6 G.C.C. Countries Europe* 2 Destination G.C.C. Countries Australia Europe* 4 Destination 1 Australia Europe* 4 General Countries* 1 General Countries* 3 Rated Voltage 12V   Output Rated 130A 150A 180A * 1 : Except for VX grade models * 2 : European models without the towing package except cold area specifications * 3 : Only on VX grade models * 4 : Only on models with towing package

EG ENGINE — 1VD-FTV ENGINE EG-175 2. Construction and Operation This generator uses a joined segment conductor system, in which multiple segment conductors are welded together at the stator. Compared to the conventional winding system, the electrical resistance is reduced due to the shape of the segment conductors, and their arrangement helps to make the generator more compact. Stator Segment Conductor Stator Segment Conductor Joined Segment Conductor System Joined A-A Cross Section Segment Conductor Type generator A A 206EG40 206EG41 Conventional Type Generator B B Stator Stator Conductor Wire B-B Cross Section Conductor Wire Wiring System Stator Segment Conductor Cross Section Stator of Segment Conductor Type Generator 206EG42 " Wiring Diagram A Generator Rectifier Rectifier Stator Rotor Regulator B IG S L M IG1 Relay Main Body ECU ECM Battery Combination Meter  Discharge Warning Light 080EG16S

ENGINE — 1VD-FTV ENGINE EG-176 3. Dual Winding System A dual winding system is used. This system consists of two sets of three-phase windings whose phases are staggered 30_. This system results in the reduction of both electrical noise (ripple and spike), and magnetic noise (a hum that is heard as alternator load is increased). This system significantly suppresses noise at the source (alternator). Because the waves that the respective windings generate have opposite polarities, magnetic noise is reduced. The magnetic noise is significantly reduced, but the electrical power generated does not cancel itself out due to the use of separate rectifiers. The opposite polarities that are generated can be seen below. 30 B A Two Sets of Three-phase Windings C Three-phase Windings Voltage Staggered 30 Voltage A B Rotational Angle C Rotational Angle Dual Winding Single Winding 279EG32

ENGINE — 1VD-FTV ENGINE EG-152 J COOLING SYSTEM 1. General D The cooling system uses a pressurized forced-circulation system with pressurized reservoir tank. D A pressurized reservoir tank is used to prevent the engine coolant from deteriorating upon contact with external air. D A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature distribution in the cooling system. D An aluminum radiator core is used for weight reduction. D A 2-stage temperature-controlled coupling fan is used. It rotates at lower speeds when the engine is started to minimize fan noise. D TOYOTA genuine SLLC (Super Long Life Coolant) is used as the engine coolant. Opening Temp. : 74 to 78C (165 to 172F) Thermostat Radiator Reservoir Tank Radiator Oil Cooler Water Pump EGR Cooler Fuel Cooler 081EG55Y

Toyota 1VD-FTV (4.5L V8) Diesel Engine Technical Training Manual

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