Toyota 1NZ-FE User manual

Brand: Toyota

Model: 1NZ-FE

Category: Measuring, testing & control

Type: User manual

ENGINE - 1NZ-FE ENGINE

00REG01Y

00REG02Y

EG-2

1NZ-FE ENGINE

DESCRIPTION

The 1NZ-FE engine is a in-line, 4-cylinder, 1.5 liter, 16-valve DOHC engine.

The VVT-i (Variable Valve Timing-intelligent) system, DIS (Direct Ignition System) and ETCS-i (Electronic

Throttle Control System-intelligent) are used on this engine in order to realize high performance, quietness,

fuel economy and clean emission.

ENGINE - 1NZ-FE ENGINE

247EG02

: IN Opening Angle

: EX Opening Angle

VVT-i Operation Angle

TDC

2

7

33

52

VVT-i Operation Angle

12

42

BDC

EG-3

 Engine Specifications 

No. of Cyls. & Arrangement 4-Cylinder, In-line

Valve Mechanism 16-Valve DOHC, Chain Drive (with VVT-i)

Combustion Chamber Pentroof Type

Manifolds Cross-Flow

Fuel System SFI

Ignition System DIS

Displacement cm

(cu. in.) 1497 (91.3)

Bore x Stroke mm (in.) 75.0 x 84.7 (2.95 x 3.33)

Compression Ratio 10.5 : 1

Max. Output*

(SAE-NET) 79 kW @ 6000 rpm (106 HP @ 6000 rpm)

Max. Torque*

(SAE-NET) 139 N

m @ 4200 rpm (103 ft lbf @ 4200 rpm)

Intake

Open -7 - 33 BTDC

Valve

Intake

Close 52 - 12 ABDC

Valve

Timing

Exhaust

Open 42 BBDC

Exhaust

Close 2 ATDC

Firing Order 1 - 3 - 4 - 2

Research Octane Number 90 or higher

Octane Rating 87 or higher

Oil Grade ILSAC

Tailpipe Emission Regulation TIRE2, ULEV-II

Evaporative Emission Regulation ORVR

Engine Service Mass*

kg (lb)

M/T 83.2 (183.4)

Engine

Service

Mass

(Reference)

(lb)

A/T 77.8 (171.5)

: Maximum output and torque rating is determined by revised SAE J1349 standard.

: Weight shows the figure with the oil fully filled.

 Valve Timing 

ENGINE - 1NZ-FE ENGINE

EG-4

FEATURES OF 1NZ-FE ENGINE

The 1NZ-FE engine has been able to achieve the following performance through the adoption of the items

listed below.

(1) High performance and fuel economy

(2) Low noise and vibration

(3) Lightweight and compact design

(4) Good serviceability

(5) Clean emission

Section

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

A cylinder block made of aluminum is used. 

Engine Proper

An offset crankshaft is used.   

roper

The taper squish shape is used for the combustion

chamber.

 

Valve

A timing chain and chain tensioner are used.   

Valve

Mechanism

The VVT-i system is used.  

Intake manifold made of plastic is used. 

The linkless-type throttle body is used.  

Intake and

A stainless steel exhaust manifold is used. 

Exhaust System

Two TWCs (Three Way Catalytic Converter) are used. 

A rearward exhaust layout is used to realize the early

activation of the catalyst.



12-hole type injector is used.  

Fuel System

The fuel returnless system is used.   

Quick connectors are used to connect the fuel hose with

the fuel pipes.



The long-reach type spark plugs are used. 

Ignition System

The DIS (Direct Ignition system) makes ignition timing

adjustment unnecessary.

  

The ETCS-i (Electronic Throttle Control

System-intelligent) is used.

 

ine Control

The non-contact sensor is used in the throttle position

sensor and accelerator pedal position sensor.



Engine

Control

System

The cranking hold function is used. 

Evaporative emission control system is used. 

The use of an air fuel ratio sensor allows for precise

control.



ENGINE - 1NZ-FE ENGINE

247EG03

Injector

Water Jacket

Taper Squish

193EG05

247EG04

Bore Center

Crankshaft Center

Crankshaft

Center

Maximum

Pressure

Offset Crankshaft Center Crankshaft

EG-5

ENGINE PROPER

1. Cylinder Head

 The injectors are installed in the cylinder head to reduce the distance from injector to intake valve, thus

it prevents the fuel from adhering to the intake port walls, and reduce exhaust emissions.

 The routing of the water jacket in the cylinder head is optimized to achieve high cooling performance.

 Through the use of the taper squish combustion chamber, the engine’s knocking resistance and fuel

efficiency have been improved.

2. Cylinder Block

 Lightweight aluminum alloy is used for the cylinder block.

 Through the use of the offset crankshaft, the bore center is shifted 12 mm (0.472 in.) towards the intake,

in relation to the crankshaft center. Thus, the side force to cylinder wall is reduced when the maximum

pressure is applied, which contributes to fuel economy.

ENGINE - 1NZ-FE ENGINE

00REG19Y

Irregularly shaped outer

casting surface of liner

Cylinder Block

Liner

A - A Cross Section

247EG06

Taper Squish Shape

Piston Ring

EG-6

 The liners are the spiny-type, which have been manufactured so that their casting exterior forms a large

irregular surface in order to enhance the adhesion between the liners and the aluminum cylinder block.

The enhanced adhesion helps improve heat dissipation, resulting in a lower overall temperature and heat

deformation of the cylinder bores.

3. Piston

 The piston is made of aluminum alloy

 The piston head portion is used a taper squish shape to accomplish fuel combustion efficiency.

 Semi floating type piston pins are used.

 By increasing the machining precision of the cylinder bore diameter, only one size of piston is available.

ENGINE - 1NZ-FE ENGINE

171EG07

Plastic Region Tightening Bolts

171EG08

Crankshaft Position

Sensor Rotor

Oil Hole

Crank Pin

No.5 Journal

Balance Weight

No.4 Journal

No.3 Journal

No.2 Journal

No.1 Journal

EG-7

4. Connecting Rod

 The connecting rods and caps are made of high

strength steel for weight reduction.

 Nutless-type plastic region tightening bolts are

used for a light design.

5. Crankshaft

 The diameter and width of the pins and journals have been reduced, and the pins for the No.1 and No.4

cylinders have been made highly rigid to realize a lightweight and low-friction performance.

 The crankshaft has 5 journals and 4 balance weights.

 A crankshaft position sensor rotor is pressed into the crankshaft to realize an integrated configuration.

ENGINE - 1NZ-FE ENGINE

165EG12171EG09

Chain

Tension Arm

Chain

Tensioner

VVT-i

Controller

Timing Chain

Exhaust Camshaft

Intake

Camshaft

Chain Guide

Camshaft

Valve Lifter

Valve

Service Tip

The adjustment of the valve clearance is accomplished by selecting and replacing the appropriate

valve lifters. Adjusting valve lifters are available in 35 increments of 0.020 mm (0.0008 in.), from

5.060 mm (0.1992 in.), to 5.740 mm (0.2260 in.).

For details, refer to 2006 Yaris Repair Manual (Pub. No. RM00R0U).

EG-8

VALVE MECHANISM

1. General

 The shimless type valve lifter is used to increase the amount of the valve lift.

 The intake and exhaust camshafts are driven by a timing chain.

 The VVT-i system is used to realize fuel economy, engine performance and reduce exhaust emissions. For

details of VVT-i control, see page EG-41.

ENGINE - 1NZ-FE ENGINE

247EG08

VVT-i Controller

Exhaust Camshaft

Timing Rotor

Intake Camshaft

Oil Passage (Advance)

Oil Passage (Retard)

247EG09

Spring

Plunger

Cam

Cam Spring

Check Ball

Chain

Slipper

Timing Chain

Chain Damper

Oil Jet

EG-9

2. Camshaft

 Oil passages are provided in the intake camshaft in order to supply engine oil to the VVT-i system.

 A VVT-i controller is provided on the front of the intake camshaft to vary the timing of the intake valves.

 A Timing rotor is provided behind the intake camshaft to trigger the camshaft position sensor.

3. Timing Chain and Chain Tensioner

 A roller type timing chain with an 8.0 mm (0.315 in.) pitch is used to make the engine compact and reduce

noise.

 The timing chain is lubricated by an oil jet.

 The chain tensioner uses a spring and oil pressure to maintain proper chain tensioner at all times. The chain

tensioner suppresses noise generated by the timing chain.

 A ratchet type non-return mechanism is used in the chain tensioner.

 Chain Tensioner 

ENGINE - 1NZ-FE ENGINE

171EG32171EG31

Service Hole for

Chain Tensioner

Front View

Oil Pump

Back View

EG-10

4. Timing Chain Cover

 A single-piece, aluminum diecast timing chain cover that entirely seals the front portion of the cylinder

block and cylinder head is used.

 A service hole for the chain tensioner is provided in the timing chain cover to improve serviceability.

ENGINE - 1NZ-FE ENGINE

171EG14

Camshaft Timing

Oil Control Valve

VVT-i

Controller

Chain

Tensioner

Oil Pump

Oil Strainer

Oil Filter

171EG15

Main Oil Hole

Crankshaft

Journal

Oil Filter

Relief

Valve

Connecting

Rod

Oil Pump

Oil Jet

Oil Strainer

Piston

Oil Jet

Cylinder Head

Camshaft Timing

Oil Control Valve

Filter

Chain

Tensioner

Timing Chain

Intake

Camshaft

Journal

Exhaust

Camshaft

Journal

Camshaft Timing

Oil Control Valve

VVT-i

Oil Pan

EG-11

LUBRICATION SYSTEM

1. General

 The lubrication circuit is fully pressurized and oil passes through an oil filter.

 A trochoid gear type oil pump, which is driven directly by the crankshaft, is provided in the front of the

cylinder block.

 The oil filter is installed diagonally downward from the side of the cylinder block to realize excellent

serviceability.

 The intake camshaft is provided with a VVT-i controller, and cylinder head is provided with a camshaft

timing oil control valve. This system is operated by the engine oil.

 Oil Capacity  Liter (US qts, Imp qts)

Dry

4.1 (4.3, 3.6)

with Oil Filter 3.7 (3.9, 3.3)

without Oil Filter 3.4 (3.6, 3.0)

 Oil Circuit 

ENGINE - 1NZ-FE ENGINE

00REG16Y

Water Pump

From Radiator

To Radiator

From Heater Core

To Heater Core

To Throttle Body

193EG08

Bypass

Passage

Water Pump

Thermostat

Cylinder Head

Cylinder Block

Radiator

Throttle

Body

Heater Core

EG-12

COOLING SYSTEM

 The cooling system is a pressurized, forced-circulation type.

 A thermostat with a bypass valve is located on the water inlet housing to maintain suitable temperature

distribution in the cooling system.

 An aluminum radiator core is used for weight reduction.

 The flow of the engine coolant makes a U-turn in the cylinder block to ensure a smooth flow of the engine

coolant.

 A single cooling fan provides both the cooling and air conditioner performance.

 The TOYOTA genuine Super Long Life Coolant (SLLC) is used.

 System Diagram 

ENGINE - 1NZ-FE ENGINE

EG-13

 Engine Coolant Specifications 

Engine

Coolant

Type

TOYOTA genuine Super Long Life

Coolant (SLLC) or similar high quality

ethylene glycol based non-silicate,

non-amine, non-nitrite and non-borate

coolant with long-life hybrid organic acid

technology (coolant with long-life hybrid

organic acid technology is a combination

of low phosphates and organic acids.) Do

not use plain water alone.

Color Pink

acit

M/T 4.8 (5.1, 4.2)

Capacity

Liters (US qts, Imp. qts)

A/T 4.7 (5.0, 4.1)

Maintenance Intervals

First Time 100,000 miles (160,000 km)

Maintenance Intervals

Subsequent Every 50,000 miles (80,000 km)

Thermostat Opening Temperature C (F) 80 - 84 (176 - 183)

 SLLC is pre-mixed (the U.S.A. models: 50 % coolant and 50 % deionized water, the Canada. models:

55 % coolant and 45 % deionized water). Therefore, no dilution is needed when SLLC in the vehicle is

added or replaced.

 If LLC is mixed with SLLC, the interval for LLC (ever 40,000 km/24,000 miles or 24 months) should

be used.

ENGINE - 1NZ-FE ENGINE

00REG06Y

Exhaust Manifold

Intake Manifold

Air Cleaner

TWCs

Sub Muffler

Main

Muffler

EG-14

INTAKE AND EXHAUST SYSTEM

1. General

 A plastic intake manifold is used for weight reduction.

 The linkless-type throttle body is used to realize excellent throttle control.

 ETCS-i (Electronic Throttle Control System-intelligent) provides excellent throttle control. For details,

see page EG-36.

 The exhaust pipe uses a ball joint in order to achieve a simple construction and reliability.

ENGINE - 1NZ-FE ENGINE

00REG03Y

Charcoal Filter

Air Cleaner Cap

Air Cleaner Element

(Nonwovens Fabric)

Service Tip

The charcoal filter, which is maintenance-free, cannot be removed from the air cleaner cap.

00REG04Y

DC Motor

Throttle Valve

Reduction Gears

Throttle Position Sensor

EG-15

2. Air Cleaner

 A nonwoven, full-fabric type air cleaner element is used.

 A charcoal filter, which adsorbs the HC that accumulates in the intake system when the engine is stopped,

is used in the air cleaner cap in order to reduce evaporative emissions.

3. Throttle Body

 The linkless-type throttle body is used and it realizes excellent throttle control.

 A DC motor with excellent response and minimal power consumption is used for the throttle control motor.

The ECM performs the duty ratio control of the direction and the amperage of the current that flows to

the throttle control motor in order to regulate the opening angle of the throttle valve.

ENGINE - 1NZ-FE ENGINE

00REG07Y

Mesh Type Gasket

00REG08Y

Ball Joint

Gasket

Ball Joint

TWCs

Front Pipe

Main Muffler

Tail Pipe

Ball Joint

Sub Muffler

EG-16

4. Intake Manifold

 The intake manifold has been made of plastic to

reduce the weight and the amount of heat

transferred from the cylinder head. As a result,

it has become possible to reduce the intake

temperature and improve the intake volumetric

efficiency.

 A mesh type gasket is used in order to reduce

the intake noise.

5. Exhaust Pipe and Muffler

A ball joint is used to joint the exhaust manifold to the exhaust front pipe, and the exhaust front pipe to the

exhaust tail pipe. As a result, a simple construction and improved reliability have been realized.

ENGINE - 1NZ-FE ENGINE

00REG12Y

Fuel Pump

 Fuel filter

 Pressure Regulator

 Fuel Sender Gauge

 Fuel Cutoff Valve

Canister

Fuel Tank

Quick Connector

Injector

View from Bottom

EG-17

FUEL SYSTEM

1. General

 The fuel returnless system is used to reduce evaporative emissions.

 A fuel tank made of multi-layer plastic is used.

 A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed in a front or side collision.

For details, see page EG-45.

 A quick connector is used to connect the fuel pipe with the fuel hose to realize excellent serviceability.

 A compact 12-hole type injector is used to ensure the atomization of fuel.

 The ORVR (On-Board Refueling Vapor Recovery) system is used. For details, see page EG-46.

ENGINE - 1NZ-FE ENGINE

179EG11

To Canister

Fuel Cutoff Valve

Fuel Filter

Fuel Pump

Injector

Pulsation

Damper

Delivery Pipe

Pressure Regulator

Fuel Tank

Module

Fuel Pump

Assembly

00REG13Y

Fuel Tank Outside

Fuel Tank Inside

HDPE (High Density Polyethylene)

Regrind Material

Adhesive

EVOH (Ethylene Vinyl Alcohol Copolymer)

Adhesive

HDPE (High Density Polyethylene)

EG-18

2. Fuel Returnless System

This system is used to reduce the evaporative emission. As shown below, integrating the fuel filter, pressure

regulator, fuel sender gauge, and fuel cutoff valve with module fuel pump assembly enables to discontinue

the return of fuel from the engine area and prevent temperature rise inside the fuel tank.

3. Fuel Tank

Low permeability has been realized through the use of the multi-layered plastic fuel tank. This fuel tank

consists of six layers using four types of materials.

ENGINE - 1NZ-FE ENGINE

165EG25

Camshaft

Position

Sensor

Crankshaft

Position

Sensor

Various

Sensor

ECM

IGT1

IGT2

IGT3

IGT4

IGF

Ignition Coil

(with Igniter)

No.1

Cylinder

No.2

Cylinder

No.3

Cylinder

No.4

Cylinder

171EG27

Igniter

Iron Core

Plug Cap

Primary Coil

Secondary Coil

EG-19

IGNITION SYSTEM

1. General

 A DIS (Direct Ignition System) is used. The DIS in this engine is an independent ignition system, which

has one ignition coil for each cylinder. The DIS ensures the ignition timing accuracy, reduces high-voltage

loss, and realizes the overall reliability of the ignition system by eliminating the distributor.

 The spark plug caps, which connect to the spark plugs, are integrated with the ignition coils. Also, the

igniters are enclosed to simplify the system.

 Long-reach type iridium-tipped spark plugs are used.

 Ignition Coil with Igniter 

ENGINE - 1NZ-FE ENGINE

281EG73

Long-Reach Type Conventional Type

Iridium Tip

EG-20

2. Spark Plug

 Long-reach type iridium-tipped spark plugs are used.

 Long-reach type of spark plugs allows the area of the cylinder head to receive the spark plugs to be made

thick. Thus, the water jacket can be extended near the combustion chamber, which contributes to cooling

performance.

 Iridium-tipped spark plugs are used to realize a 100,000 km (62,500 mile) maintenance-free operation.

By making the center electrode of iridium, the same ignition performance as the platinum-tipped type

spark plug and excellent of durability have been realized.

 Specification 

DENSO SK16R11

NGK IFR5A-11

Plug Gap mm (in.) 1.1 (0.043)

ENGINE - 1NZ-FE ENGINE

206EG41206EG40

Stator

Segment

Conductor

Stator

Segment

Conductor

Joined

Joined Segment

Conductor System

A - A Cross

Section

Segment Conductor

Type Generator

Stator

Conductor Wire

Wiring System

B - B Cross

Section

Conventional Type Generator

Stator

Segment

Conductor

Cross Section

206EG42

Stator of Segment Conductor

Type Generator

EG-21

CHARGING SYSTEM

 A compact and lightweight segment conductor type generator that generates high amperage output in a

highly efficient manner is used as standard equipment.

 This generator has a joined segment conductor system, in which multiple segment conductors are welded

together to form the stator. Compared to the conventional wiring system, the electrical resistance is

reduced due to the shape of the segment conductors, and their arrangement helps to make the generator

compact.

 Specifications 

Type SE08

Rated Voltage 12 V

Rated Output 80 A

Initial Output Starting Speed 1,250 rpm Max.

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Toyota 1NZ-FE User manual

Brand: Toyota

Model: 1NZ-FE

Category: Measuring, testing & control

Type: User manual

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Toyota 1NZ-FE User manual

Toyota 1NZ-FE User manual

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