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 SpecificationA

Model With DPF Without DPF

Number of Cylinders & Arrangement 4-cylinder, In-line z
16-valve DOHC z
ValveMechanism
Chain and Gear Drive
Combustion Chamber Direction Injection Type z
Manifolds Cross-flow z
Fuel System Common-rail Type z
Displacement cm3(cubic inches) 1998 z
BorexStroke mm (in.) 86.0x86.0 (3.39x3.39) z
Compression Ratio 16.8 : 1 z
Max. Output (EEC) 93 kW @ 3600 rpm z
Max. Torque (EEC) 300 N.m @ 1800 – 2400 rpm 300 N.m @ 2000 - 2800 rpm
Open 2_BTDC z
Intake
Valve Close 31_ABDC z
Timing Open 51_BBDC z
Exhaust
Close 2_ATDC z
G-DLD1 or ACEA B1
Oil Grade ACEA B1, C2 (Prefer)*1
API CF-4 or CF
Firing Order 1–3–4–2 z
Fuel Cetane Number 48 or more z
Emission Regulation EURO IV*2 EURO IV
Engine Service Mass
kg (lb) 152 (335) 147 (324)
(Reference)
*1When you use non-recommended oil such as API CF grade, you may need extra maintenance for DPF.
Recommended oil viscosity: 5W-30
*2PM: 80% less than EURO IV regulations
 AVENSIS– NEW FEATURES 7

" Valve TimingA

INValve Opening Angle

EXValve Opening Angle
TDC
2_2_

51_
31
BDC
288EG03Y

" Performance CurveA

120
110
400 100
350 90
300 80
Torque 250 70
(N.m) Output
200 60 (kW)
150 50
100 40
30
20
10
0
1000 2000 3000 4000 5000

Engine Speed (rpm)

02JEG22Y
8 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.
High performance and reliability
Low noise and vibration
Lightweight and compact design
Good serviceability
Clean emission and fuel economy

Without
Item (1) (2) (3) (4) (5)
DPF DPF
A cylinder head and cylinder block made of
f f f
aluminum alloy are used.
Engine
Piston provided with combustion chamber
Proper
is used in conjunction with the adoption of f f f f
direct injection.
Hydraulic lash adjuster is used. f f f f f
Valve
A timing chain and chain tensioner are used. f f f f f
Mechanism
Roller rocker arms are used. f f f f
An oil filter with a replaceable element is
Lubrication f f f
used.
System
The water-cooled type oil cooler is used. f f f
Cooling TOYOTA Genuine SLLC (Super Long Life
f f f
System Coolant is used.
A rotary solenoid type diesel throttle control
f f f
A motor is used in the throttle body.
A linear solenoid type EGR valve is used. f f f
A water-cooled type EGR cooler is used. f f f
Intake and
Exhaust A water-cooled type EGR cooler with a
f f —
System bypass is used.
The variable nozzle vane type turbocharger
f f f f
is used.
The exhaust manifold converter uses
f f —
oxidation catalyst and DPF catalyst.
A common-rail type fuel injection system is
f f f f f
used.
Fuel Solenoid type injectors on which
System compensation value and QR code are f f f f
printed are used.
An exhaust fuel addition injector is used. f f —
A segment conductor type alternator is
f f f f
Charging used.
System An alternator pulley with a one-way clutch
f f f
is used.
(Continued)
 AVENSIS– NEW FEATURES 9

With Without
Item (1) (2) (3) (4) (5)
DPF DPF
Serpentine
Belt Drive A serpentine belt drive system is used. f f f f
System
A pilot injection control system is used. f f
Engine An oil maintenance management system is
f f f
Control used.
System A charging control system is used. f f f
A catalyst support control is used. f f —

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 A

View from A
Cylinder Head
288EG73Y
10 AVENSIS– NEW FEATURES

4. Intake and Exhaust System

General
DA bypass path with a switching valve is added to the EGR cooler.
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.
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 Water

Cooler Side Gas

Exhaust Gas OUT Outlet for

Bypass Side Gas
EGR Cooler
Water OUT A – A Cross Section
02JEG23Y

Exhaust Manifold Converter

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

Exhaust Gas
PM

Oxidation Catalyst Filter

DPF Catalyst

02JEG08Y
 AVENSIS– NEW FEATURES 11

5. Fuel System

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

Supply Pump Fuel Tank

Injector

EDU

Quick Connectors

Common rail
DFuel 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 DiagramA

Fuel Pressure Sensor Pressure Limiter

Common rail

Fuel Temperature Sensor

Supply
Pump

Exhaust Fuel
Addition Injector* Injector

Fuel
Filter EDU
Engine
Fuel Tank ECU

02JEG11Y

Only for DPF Models

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

Fuel Outlet

288EG101Y
 AVENSIS - NEW FEATURES 13

Exhaust Fuel Addition Injector

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 Solenoid Valve
(Particulate Matter) recovery.
An exhaust fuel addition injector consists
of a needle valve body, needle valve, and Needle Valve
solenoid valve.

Needle Valve Body

288EG89Y
14 AVENSIS–NEWFEATURES

6. Engine Control System

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

With Without
System Outline
DPF DPF
Based on the signals received from the sensors, the
Fuel Injection
engine ECU determines the fuel injection volume in f f
VolumeControl
accordance with the engine condition.
Based on the signals received from the sensors, the
Fuel Injection
engine ECU determines the fuel injection timing in f f
Timing Control
in accordance with the engine condition.
Based on the signals received from the sensors, the
Fuel Pressure
engine ECU controls fuel pressure using the SCV f f
Control
according to engine conditions.
Based on the signals received from the various sensors,
Pilot Injection the engine ECU determines pilot injection volume,
f f
Control timing, and interval (between pilot injection and main
injection) in accordance with the engine condition.
Catalyst Support Based on the signals received from the sensors, the
Control engine ECU controls exhaust fuel addition injector to f —
(See page 24) purify PM.
The engine ECU determines the idle speed in accordance
Idle Speed Control with the engine condition, and controls the fuel injection f f
volume in order to maintain the target idle speed.
Controls the length of time when the current is applied
Glow Plug Control f f
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
— f
and diesel throttle control valve in accordance with the
EGR Control engine condition.
(See page 25) Based on the signals received from the sensors, the
engine ECU determines the EGR volume via EGR valve,
f —
EGR cooler bypass switching valve and diesel throttle
control valve in accordance with the engine condition.
Based on the signals received from the sensors, the
Turbo Pressure
engine ECU controls the actuator via E-VRV in f f
Control
accordance with the engine condition.
Based on the signals received from the various
sensors, the engine ECU determines throttle position
Intake Throttle
in accordance with engine condition. f f
Control DFully closes the diesel throttle control valve in order
to reduce the vibration when the engine is stopped.
(Continued)
 AVENSIS–NEWFEATURES 15

With Without
System Outline
DPF DPF
The engine ECU regulates the charging voltage of the
Charging Control alternator in accordance with the driving conditions and f f
the charging state of the battery
Maintains the temperature of the air-fuel ratio sensor at
Air-fuel Ratio Sensor
an appropriate level to increase accuracy of detection of f —
Heater Control
the oxygen concentration in the exhaust gas.
By controlling the air conditioner compressor ON or
Air Conditioner
OFF in accordance with the engine condition, drivability f f
Cut-off Control
is maintained.
Engine Prohibits fuel injection if an attempt is made to start the
f f
Immobilizer engine with an invalid ignition key.
Oil Maintenance When the engine ECU determines engine oil
Management deterioration, the engine oil change reminder light turns f f
System ON to inform the driver.
Diagnosis When the engine ECU detects a malfunction, the engine
f f
(See page 26) The ECU diagnoses and remembers the failed section.
When the engine ECU detects a malfunction, the engine
Fail-safe
ECU stops or controls the engine according to the data f f
(See page 26)
already stored in the memory.
16 AVENSIS– NEW FEATURES

Construction
The configuration of the engine control system is as shown in the following chart.
SENSORS ACTUATORS
#1
VG No. 1 INJECTOR
AIR FLOW METER #2
No. 2 INJECTOR
ATMOSPHERIC THA #3
EDU No. 3 INJECTOR
TEMPERATURE SENSOR #4
No. 4 INJECTOR
INJF
INTAKE AIR TEMPERATURE THIA
SENSOR

WATER TEMPERATURE SENSOR THW IREL

EDU RELAY
CRANKSHAFT POSITION NE
SENSOR
G FIV EXHAUST FUEL
CAMSHAFT POSITION SENSOR ADDITION INJECTOR*

ACCELERATOR PEDAL VPA

POSITION SENSOR VPA2
PCV
SUCTION CONTROL VALVE
DIESEL THROTTLE POSITION VLU
SENSOR

THF INTAKE THROTTLE CONTROL

FUEL TEMPERATURE SENSOR
ENGINE LUSL DIESEL THROTTLE
PCR1 ECU CONTROL MOTOR
FUEL PRESSURE SENSOR

PIM
TURBO PRESSURE SENSOR
GLOW PLUG CONTROL
EGLS
EGR VALVE POSITION SENSOR GREL
GLOW PLUG RELAY
DIFFERENTIAL PRESSURE PEX
SENSOR*

EXHAUST GAS TEMPERATURE THCI EGR CONTROL

SENSOR (UP SIDE)*
EGRS
EGR VALVE
EXHAUST GAS TEMPERATURE THCO
SENSOR (LOWER SIDE)* ECBV VSV (FOR EGR COOLER
BYPASS SWITCHING VALVE)
ALT
ALTERNATOR RL

BATTERY TEMPERATURE THB

SENSOR TURBOCHARGER CONTROL

IB VN E-VRV
BATTERY CURRENT SENSOR

(Continued)
Only for DPF Models 02JEG09Y
 AVENSIS - NEW FEATURES 17

CLSW
CLUTCH SWITCH

CCS CHARGING CONTROL

CRUISE CONTROL SWITCH
RLO ALTERNATOR
(IC REGULATOR)
TRC
SKID CONTROL ECU

AF2
AIR-FUEL RATIO SENSOR*

STP AIR-FUEL RATIO SENSOR

STOP LIGHT SWITCH HEATER CONTROL
HAF2 AIR-FUEL RATIO
POWER STEERING OIL PSP SENSOR HEATER
PRESSURE SENSOR

ELS
TAIL LAMP RELAY

PTC ENGINE
ECU COOLING FAN CONTROL
AIR CONDITIONER ECU MPX2
FAN
COOLING FAN RELAY

IGNITION SWITCH
STA
DStarter Signal IGSW
Dignation Signal

MREL
COMBINATION METER SPD MAIN RELAY
DVehicle Speed Signal +B

IMI
TRANSPONDER KEY ECU In My Opinion
MPX1
SIL, TC COMBINATION METER
DLC3 WFSE W CHECK ENGINE
WARNING LIGHT

BATT
BATTERY
02JEG10Y

BEAN

Only for DPF Models

18 AVENSIS– NEW FEATURES

Engine Control System Diagram

Combination Meter
DVehicle Speed Signal
Accelerator Pedal Check Engine Warning Light
Position Sensor DGlow Indicator Light
Engine Oil Change Reminder Light

Fuel Temperature
BEAN BEAN
Sensor
Air Conditioner
ECU Supply Pump
Tail Light Relay
Alternator
Stop Light Relay Cooling Fan Relay
Starter Relay
Ignition
Switch
Main Relay Fuel Pressure Sensor
SCV
Battery Current Sensor
Engine
Battery Temperature Sensor ECU
Common-rail
Battery DLC3
Power Steering Oil Pressure Sensor

EDU Relay
EDU

Intake Air
Temperature
Sensor Diesel Throttle
Atmospheric Temperature Control Motor
Sensor

EGR Valve
VSV (For EGR Cooler)
Air Flow Meter Bypass Switching Valve)
Injector

Actuator Throttle
Camshaft Position
Position Sensor Turbo Pressure
Sensor
Sensor
E-VRV
(For Turbocharger Control)
Glow
Exhaust Temperature Sensor Exhaust Fuel Plug
(Up Side)* Addition
Exhaust Temperature Sensor Injector* Water
(Lower Side)* Temperature
Sensor
Differential
Pressure Sensor* Glow
Relay

Crankshaft Position
Sensor
Air-fuel Ratio Sensor*

02JEG13Y

Only for DPF Models

 AVENSIS– NEW FEATURES 19

Layout of Main Components

Air Flow Meter
Battery Current Sensor

Differential
Pressure Sensor*

EDU

Intake Air Temperature Air-fuel Ratio Sensor

Sensor Battery Temperature Sensor

Check Engine
Glow Plug Indicator Warning Light

Engine Oil Change Engine ECU

Reminder Light

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
Turbo Pressure Sensor
Sensor

EGR Valve

Diesel Throttle Position Sensor

E-VRV VSV (For EGR Cooler)

(For Turbocharger Control) Bypass Switching Valve

Camshaft Position Sensor

Exhaust Temperature
Sensor (Up Side)*

Exhaust Temperature
Sensor (Lower Side)*

Crankshaft
Position Sensor
02JEG20Y

Only for DPF Models

 AVENSIS– NEW FEATURES 21

Main Component of Engine Control System

1) General

The main components of the 1AD-FTV engine control system are as follows:

Components Outline Quantity

Engine ECU 32-bit CPU 1
EDU Including a built-in DC-DC converter 1
Air Flow Meter Hot-wire Type 1
Crankshaft Position Sensor (Rotor Teeth) Pick-up Coil Type (36 – 2) 1
Camshaft Position Sensor (Rotor Teeth) Pick-up Coil Type (1) 1
Semiconductor Strain Gauge Type
Fuel Pressure Sensor 1
Two Circuits Type
Accelerator Pedal Position Sensor Linear (Non-contact) Type 1
Diesel Throttle Position Sensor Linear (Non-contact) Type 1
Differential Pressure Sensor* Semiconductor Strain Gauge Type 1
Up Side
Exhaust Gas Temperature Sensor* Thermistor Type 1 each
Lower Side
Air-fuel Ratio Sensor Type with heater (Planar Type) 1
Only for DPF Models

2) Differential Pressure Sensor

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

Differential Pressure Sensor

02JEG25Y

(V)
4.65

Voltage

(kPa)
0 100
Pressure 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
(Ω)
103

102
0 100 200 300 400 500 600 700 800 900

Exhaust Gas Temperature (_C)

258AE40
258AE41

Air-fuel Ratio Sensor

a. General
The planar type air-fuel ratio sensor is used.
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.
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
The sensor, which is mounted after the DPF catalyst, detects the air-fuel ratio after the gases are reduced.

Alumina
Dilation Layer
Atmosphere

Alumina

Heater

Platinum
Electrode
Sensor Element (Zirconia) 288EG86Y
 AVENSIS– NEW FEATURES 23

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 ratio sensor converts the oxygen density to 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.

(V)
4.2

Air-fuel Ratio Sensor Data

Displayed on Intelligent
Tester II

2.2

11 (Rich) 14.7 19 (Lean)

Air-fuel Ratio 258AE59
24 AVENSIS - NEW FEATURES

Catalyst Support Control

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.
The catalyst support control consists of the PM reduction control.
Injector
Water Temperature
Exhaust Fuel Addition Injector Sensor
Air Flow Meter

Engine ECU

Exhaust Gas
Temperature
Sensors

Air-fuel Ratio
Sensor

Differential Pressure Sensor 288EG67C

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.
At the same time, filter substrate temperature becomes high and PM reacts with active oxygen and
changes into CO2for purification.
Fuel efficiency drops during this control.

Service Tip
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.
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 deteriorates, data history is not
transferred, DTC (Diagnostic Trouble Code) P1601 is stored in the engine ECU, and the check
engine warning light comes on.
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 deteriorates, 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).
 AVENSIS - NEW FEATURES 25

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

Air Flow Meter

EGR Valve
Engine
ECU
Water Temperature Sensor

Atmospheric Temperature
Sensor
EGR Cooler Bypass
Switching Valve Turbo Pressure Sensor

EGR Cooler

Engine To Turbocharger

Exhaust Gas 288EG103C

26 AVENSIS - NEW FEATURES

Diagnosis
The diagnosis uses the EURO-OBD (Europe On-Board Diagnosis) that complies with European
regulations.
When the engine ECU detects a malfunction, the engine ECU generates DTCs (Diagnostic Trouble Codes)
and memorizes the failed section. Furthermore, the check engine warning light in the combination meter
illuminates to inform the driver.
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.
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
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).