Toyota tundra – new features

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Toyota tundra – new features is a 4.6-liter, 32-valve DOHC V8.This engine uses the Dual Variable Valve Timing-intelligent (Dual VVT-i) system, Direct Ignition System (DIS), Acoustic Control Induction System (ACIS), Electronic Throttle Control System-intelligent (ETCS-i), air injection system and Exhaust Gas Recirculation (EGR) control. These control functions achieve improved engine performance, fuel economy, and clean emissions.

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TOYOTA TUNDRA – NEW FEATURES 13 NEW FEATURES J1UR-FE ENGINE 1. Description The 1UR-FE engine is a 4.6-liter, 32-valve DOHC V8. This engine uses the Dual Variable Valve Timing-intelligent (Dual VVT-i) system, Direct Ignition System (DIS), Acoustic Control Induction System (ACIS), Electronic Throttle Control System-intelligent (ETCS-i), air injection system and Exhaust Gas Recirculation (EGR) control. These control functions achieve improved engine performance, fuel economy, and clean emissions. 12CEG01Y 12CEG02Y
14 TOYOTA TUNDRA – NEW FEATURES " Engine Specifications A No. of Cyls. & Arrangement 8-cylinder, V Type Valve Mechanism 32-valve DOHC, Chain Drive (with Dual VVT-i) Combustion Chamber Pentroof Type Manifolds Cross-flow Fuel System SFI Ignition System DIS Displacement cm3 (cu. in.) 4608 (281.2) Bore × Stroke mm (in.) 94.0 × 83.0 (3.70 × 3.27) Compression Ratio 10.2 : 1 Max. Output (SAE-NET)*1 231 kW @ 5600 rpm (310 HP @ 5600 rpm) Max. Torque (SAE-NET)*1 443 N⋅m @ 3400 rpm (327 ft⋅lbf @ 3400 rpm) Open –18_ to 22_ BTDC Intake Closed 70_ to 30_ ABDC Valve Timing Open 62_ to 30_ BBDC Exhaust Closed – 8_ to 24_ ATDC Firing Order 1–8–7–3–6–5–4–2 Octane Rating 87 or higher Research Octane Number (RON) 91 or higher Tailpipe Emission Regulation LEVII-ULEV, SFTP Evaporative Emission Regulation LEVII, ORVR Engine Service Mass*2 (Reference) kg (lb) 216.1 (476.5) *1: Maximum output and torque ratings are determined by revised SAE J1349 standard. *2: The figure shown is the weight of the part without coolant and oil.
TOYOTA TUNDRA – NEW FEATURES 15 " Valve Timing A : Intake valve opening angle : Exhaust valve opening angle Exhaust VVT-i Intake VVT-i Operation Range Operation Range TDC 8_ 18_ 22_ 24_ 70_ 62_ Intake VVT-i Exhaust VVT-i Operation Range 30_ 30_ Operation Range BDC 12CEG03Y " Performance Curve A 320 240 300 220 280 340 200 460 260 440 320 180 420 240 Torque 400 300 220 N⋅m (ft⋅lbf) 380 280 160 360 260 200 340 240 180 140 Output 320 (HP) kW 160 120 140 100 120 80 100 80 60 60 40 40 20 20 0 0 1000 2000 3000 4000 5000 6000 Engine Speed (rpm) 12CEG53Y
16 TOYOTA TUNDRA – NEW FEATURES 2. Features of 1UR-FE Engine The 1UR-FE engine has achieved the following performance through the use 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) A taper squish shape is used for the combustion chamber. f f An aluminum alloy cylinder block containing an engine f f coolant distribution pathway is used. Engine Proper Spiny-type liners are used in the cylinder bores. f f Cylinder block water jacket spacers are used. f The piston skirt is coated with resin. f f f A No. 1 oil pan made of aluminum alloy is used. f f f Timing chains and chain tensioners are used. f f Valve Hydraulic lash adjusters are used. f f f f Mechanism Roller rocker arms are used. f f Lubrication An oil filter with a replaceable element is used. f System A water-cooled type oil cooler is used.* f A carbon filter is used in the air cleaner cap. f A linkless-type throttle body is used. f f An intake manifold made of plastic is used. f f Intake and A step motor type EGR valve is used. f Exhaust System A water-cooled type EGR cooler is used. f Stainless steel exhaust manifolds are used. f f f Ceramic type Three-Way Catalytic converters (TWCs) f are used. 12-hole type fuel injectors are used to improve the Fuel System f f atomization of fuel. The Direct Ignition System (DIS) makes ignition timing f f f Ignition System adjustment unnecessary. Long-reach type iridium-tipped spark plugs are used. f f f (Continued) *: Models with towing package
TOYOTA TUNDRA – NEW FEATURES 17 Item (1) (2) (3) (4) (5) Charging A segment conductor type generator is used. f f System Starting System A planetary reduction type starter is used. f Serpentine Belt A serpentine belt drive system is used. f f Drive System Blowby Gas A separator case is provided between the cylinder block Ventilation f f and the intake manifold. System An magnetic Resistance Element (MRE) type crankshaft f position, a camshaft position, and VVT sensors are used. The Electronic Throttle Control System-intelligent f f (ETCS-i) is used. The Dual Variable Valve Timing-intelligent (Dual Engine Control f f VVT-i) system is used. System The Acoustic Control Induction System (ACIS) is used. f f The Exhaust Gas Recirculation (EGR) control is used. f An air injection system is used. f A starter control (cranking hold function) is used. f An evaporative emission control system is used. f
18 TOYOTA TUNDRA – NEW FEATURES 3. Engine Proper Cylinder Head Cover D Lightweight yet high-strength aluminum cylinder head covers are used. D An oil delivery pipe is installed inside the cylinder head covers. This ensures lubrication to the sliding parts of the valve rocker arms, improving reliability. D Large baffle plates are built into the cylinder head covers. As a result, the speed of blowby gas flow is reduced, and the oil mist is removed from the blowby gas. Due to this, the amount of oil lost is reduced. Cylinder Head Cover LH Cylinder Head Cover RH Oil Delivery Pipe Baffle Plate Baffle Plate Oil Delivery Pipe Cylinder Head Cylinder Head Cover Gasket RH Cover Gasket LH 12CEG04Y Cylinder Head Gasket D 3-layer steel-laminate type cylinder head gaskets are used. A shim is used around the cylinder bore of each gasket to help enhance sealing performance and durability. This results in improved fuel economy, reduced consumption rate of engine oil and reduced emission of exhaust gases. D The surface is coated with highly heat-resistant fluoro rubber to support high power output. A A Shim Right Bank Front A – A Cross Section Left Bank 04E1EG07C
TOYOTA TUNDRA – NEW FEATURES 19 Cylinder Head D The cylinder head structure has been simplified by separating the cam journal portion (camshaft housing) from the cylinder head. D The cylinder head, which is made of aluminum, contains a pentroof type combustion chamber. The spark plug is located in the center of the combustion chamber in order to improve the engine’s anti-knocking performance. D The port configuration is an efficient cross-flow type in which the intake ports face the inside of the V bank and the exhaust ports face the outside. D A siamese type intake port is used. The port diameter gradually decreases toward the combustion chamber to optimize the airflow speed and intake pulsation. D An air injection port is provided for the air injection system. Camshaft Housing Intake A Intake Side Valve Intake Side Spark Plug Hole Exhaust Side Exhaust Exhaust Side Valve A Bottom Side View 080EG31TE A – A Cross Section 04E1EG09C Air Injection Port Front Exhaust Side View 04E1EG10C — REFERENCE — Siamese Type Independent Type 036EG28TE 036EG29TE
20 TOYOTA TUNDRA – NEW FEATURES Cylinder Block 1) General D The cylinder block is made of aluminum alloy. D The cylinder block has a bank angle of 90_, a bank offset of 21 mm (0.827 in.) and a bore pitch of 105.5 mm (4.15 in.), resulting in a compact block in its length and width considering its displacement. D Spiny-type liners are used. D An engine coolant distribution pathway is provided between the left and right banks. The engine coolant sent by the water pump passes through the engine coolant distribution pathway and flows to the cylinder head and water jackets of both banks. The engine coolant distribution pathway also cools the engine oil in the main oil hole located directly below the pathway. D A water passage is provided between the cylinder bores. By allowing the engine coolant to flow between the cylinder bores, this construction keeps the temperature of the cylinder walls uniform. D Plastic cylinder block water jacket spacers are inserted in the water jacket. They control the flow of the engine coolant in order to attain a uniform temperature around the combustion chambers. D Installation bosses of the 4 knock sensors are located on the inner side of the left and right banks to enhance the accuracy of the knock sensors. D Air passage holes are provided on the bulkheads of the cylinder block. As a result, the air at the bottom of the cylinder flows smoother, and pumping loss (back pressure at the bottom of the piston generated by the piston’s reciprocating movement) is reduced to improve the engine’s output. Water Passage 105.5 mm Knock Sensor 21 mm (4.15 in.) Boss (0.827 in.) #2 #4 #6 #8 #1 #3 #5 #7 Engine Coolant Distribution Pathway Top Side View Air Passage Hole 90_ Main Oil Hole 12CEG05Y
TOYOTA TUNDRA – NEW FEATURES 21 2) Spiny-type Liner D The liners are the spiny-type which have been manufactured so that their casting exteriors form large irregular surfaces in order to enhance the adhesion between the liners and the aluminum cylinder block. The enhanced adhesion helps heat dissipation, resulting in a lower overall temperature and heat deformation of the cylinder bores. D The shape of the cross-hatching of the liner surface has been optimized to improve oil retention performance, resulting in reduced friction. Irregularly Shaped Cylinder Block Cylinder Block Outer Casting Surface of Liner A Enlarged View of Cross-hatching A Liner A – A Cross Section 12CEG06Y 3) Cylinder Block Water Jacket Spacer The temperature in the intake side of the cylinder bore tends to be lower. For this reason, a wide cylinder block water jacket spacer covers the cylinder bores in order to suppress the flow of the engine coolant and prevent excessive cooling. On the other hand, the temperature of the exhaust side of the cylinder bore tends to be higher. A cylinder block water jacket spacer covers the lower area of the cylinder bores in order to direct the engine coolant to the upper area of the cylinder bores where the temperature is higher. This makes the temperature around the cylinder bores more uniform. As a result, the viscosity of the engine oil (which lubricates the area between the wall surface of the cylinder bore and the piston) decreases, thus reducing friction between the cylinder bore and the piston. Cylinder Block Water Jacket Water Jacket Spacer Intake Side Exhaust Side Cylinder Block Water Jacket Spacer : Engine coolant flow Front : Engine coolant Cross-sectional Image of Cylinder Bore 12CEG07Y
22 TOYOTA TUNDRA – NEW FEATURES Piston D The pistons are made of aluminum alloy. D A compact combustion chamber is provided on top of the piston to achieve stable combustion. Together with the pentroof type combustion chamber of the cylinder head, this achieves a high compression ratio, resulting in both high performance and excellent fuel economy. D A taper squish combustion chamber is used to improve anti-knocking performance and intake efficiency. In addition, engine performance and fuel economy are improved. D In order to reduce weight, cast holes are provided on the bottom of the piston head near the pin bosses as shown in the illustration below. D The piston skirt is coated with resin to reduce friction losses. D A Physical Vapor Deposition (PVD) coating has been applied to the surface of the No. 1 compression ring and oil ring, in order to improve its wear resistance. D By increasing the machining precision of the cylinder bore diameter in the block, only one size of piston is required. Resin Coating PVD Coating Taper Squish Shape No. 1 Compression Ring Weight Reduction Area No. 2 Compression Ring Oil Ring PVD Coating 12CEG17I Service Tip The same pistons are used for both right and left banks. When installing a piston, the front mark should face the front of the engine.
TOYOTA TUNDRA – NEW FEATURES 23 Connecting Rod and Connecting Rod Bearing D Connecting rods that have been forged for high strength are used for weight reduction. D Knock pins are used at the mating surfaces of the bearing caps of the connecting rod to minimize the shifting of the bearing caps during assembly. D Plastic region tightening bolts are used on the connecting rods. D Resin-coated aluminum bearings are used for the connecting rod bearings. The connecting rod bearings are reduced in width to reduce friction. Knock Pin Resin Coating Oil Jet Plastic Region Tightening Bolt 12CEG11Y Crankshaft D A crankshaft made of forged steel, which excels in rigidity and wear resistance, is used. D The crankshaft has 5 main bearing journals and 6 balance weights. Balance Weight Balance Weight Engine Front No. 1 Journal No. 3 Journal No. 5 Journal No. 4 Journal No. 2 Journal 036EG02TE
24 TOYOTA TUNDRA – NEW FEATURES Crankshaft Bearing and Crankshaft Bearing Cap D The crankshaft bearings are made of aluminum alloy. D The crankshaft bearings are reduced in width to reduce friction. The bearing lining surface is coated with resin to improve wear and seizure resistance. D The upper crankshaft bearing has an oil groove around its inside circumference. D The crankshaft bearing caps use 4 plastic region tightening bolts of different sizes in the inner and outer sides to secure the journals. This makes the crankshaft bearing caps more compact and lightweight. In addition, each cap has been tightened laterally to improve its reliability. Plastic Region Tightening Bolt Upper Main Bearing Oil Groove Resin Coating Crankshaft Bearing Cap Lower Main Bearing 12CEG08Y Crankshaft Pulley The crankshaft pulley uses torsional damper Torsional Damper rubber and has been optimized to reduce noise Rubber and vibration. 04E1EG18C
TOYOTA TUNDRA – NEW FEATURES 25 Oil Pan D The No. 1 oil pan is made of aluminum alloy. D The No. 1 oil pan is secured to the cylinder block and the transmission housing to increase rigidity. D The shape of the oil pan baffle plate has been optimized to ensure the proper space between the crankshaft and the engine oil surface. This enhances the separation of oil flow and ventilation gases, thus reducing friction and improving lubrication performance. Oil Pan Baffle Plate No. 1 Oil Pan No. 2 Oil Pan 080EG02TE
26 TOYOTA TUNDRA – NEW FEATURES 4. Valve Mechanism General D Each cylinder of this engine has 2 intake valves and 2 exhaust valves. Intake and exhaust efficiency has been increased due to the larger total port areas. D This engine uses roller rocker arms with built-in needle bearings. This reduces the friction that occurs between the cams and the valve rocker arms that push the valves down, thus improving fuel economy. D A hydraulic lash adjuster, which maintains a constant zero valve clearance through the use of oil pressure and spring force, is used. D To ensure highly accurate valve timing, separate primary timing chains are driven by the crankshaft in order to rotate the intake camshafts of the left and right banks. The exhaust camshafts are driven by the intake camshaft of the respective bank via secondary timing chains. D This engine has a Dual Variable Valve Timing-intelligent (Dual VVT-i) system which controls the intake and exhaust camshafts to provide optimal valve timing in accordance with driving conditions. Using this system, lower fuel consumption, higher engine performance, and lower exhaust emissions have been achieved. For details of Dual VVT-i control, see page 78. Intake Camshaft Exhaust Camshaft Secondary Timing Chain Valve Rocker Arm Valve Spring Retainer Hydraulic Lash Adjuster Compression Spring Valve Guide Bush Valve Spring Seat Valve Primary Timing Secondary Timing Chain Chain 12CEG18Y
TOYOTA TUNDRA – NEW FEATURES 27 Camshaft D The camshafts are made of cast iron alloy. D Oil passages are provided in the intake and exhaust camshafts in order to supply engine oil to the VVT-i system. D VVT-i controllers are installed on the front of the intake and exhaust camshafts to vary the timing of the intake and exhaust valves. D Together with the use of the roller rocker arms, the cam profile has been optimized. This results in increased valve lift when the valve begins to open and when it finishes closing, helping to achieve enhanced output performance. No. 2 Camshaft Increased Valve Lift No. 1 Camshaft (Exhaust) VVT-i (Intake) Controller No. 3 Camshaft (Intake) Optimized Profile of Camshaft Lobe Timing Rotor VVT-i Controller Timing No. 4 Camshaft Rotor (Exhaust) Oil Passage VVT-i Controller Cross Section of End of Intake Camshaft Oil Passage Cross Section of End of Exhaust Camshaft 080EG34S
28 TOYOTA TUNDRA – NEW FEATURES Timing Chains and Chain Tensioners D Both the primary and secondary timing chains use roller chains with a pitch of 9.525 mm (0.375 in.). D A chain tensioner is provided for each primary timing chain and secondary timing chain in each bank. D Both the primary and secondary chain tensioners use oil pressure and a spring to maintain proper chain tension at all times. The tensioners suppress noise generated by the timing chains. D The chain tensioner for the primary timing chain is a ratchet type with a non-return mechanism. Furthermore, an oil pocket creates oil pressure when the engine is started, and simultaneously applies oil pressure to the chain tensioner. This prevents the timing chain from flapping and reduces noise. Primary Chain Tensioner LH Gasket Chain Tensioner Oil Pocket Secondary Chain Tensioner RH (Primary) Secondary Chain Main Chain Damper RH Chain Slipper LH Tensioner LH Spring Ball Secondary Timing Chain RH Ball Plunger Spring Primary Chain Tensioner RH Secondary Timing Spring Chain LH Chain Slipper RH Chain Damper LH Cam Primary Timing Cam Spring Primary Timing Chain LH Chain RH 080EG23S
TOYOTA TUNDRA – NEW FEATURES 29 Timing Chain Cover D The timing chain cover has an integrated construction consisting of a cooling system (water pump and water passage) and a lubrication system (oil pump and oil passage). Thus, the number of parts has been reduced, resulting in a weight reduction. D A chain oil jet is provided in the oil pump cover to lubricate the timing chains. Water Pump Timing Chain Cover Water Pump Swirl Chamber Gasket Oil Pump Chain Cover Oil Jet Water Pump Oil Pump Chamber Timing Chain Cover Oil Pump Rotor Front Side View Back Side View 12CEG12Y Hydraulic Lash Adjuster D The hydraulic lash adjuster, which is located at the fulcrum (pivot point) of the roller rocker arms, consists primarily of a plunger, a plunger spring, a check ball, and a check ball spring. D The engine oil supplied from the cylinder head and the built-in spring actuate the hydraulic lash adjuster. The oil pressure and the spring force, that act on the plunger, push the roller rocker arm against the cam, in order to adjust the clearance between the valve stem and rocker arm. This prevents the generation of noise during the opening and closing of the valves. As a result, engine noise has been reduced. Plunger Cam Hydraulic Lash Roller Rocker Arm Adjuster Oil Passage Oil Passage Check Ball Check Ball Spring Plunger Spring 04E1EG24C Service Tip Valve clearance adjustment is not necessary because hydraulic lash adjusters are used on this model.
30 TOYOTA TUNDRA – NEW FEATURES 5. Lubrication System General D The lubrication circuit is fully pressurized and oil passes through an oil filter. D A cycloid rotor type oil pump is used. D An oil filter with a replaceable element is used. D A water-cooled type oil cooler is provided as optional equipment. Oil Delivery Pipe (Cylinder Head Cover) Camshaft Timing Oil Control Valve Oil Pump Oil Filter Oil Strainer Oil Cooler* *: Models with towing package 12CEG19Y
TOYOTA TUNDRA – NEW FEATURES 31 " Oil Circuit A Main Oil Hole Chain Cylinder Block Cylinder Head LH Cylinder Head RH Oil Jet Oil Crankshaft Primary Camshaft Intake Camshaft Intake Primary Chain Timing Camshaft Timing Camshaft Chain Filter Journals Tensioner OCV*2 Journals OCV*2 Journals Tensioner Oil VVT-i Exhaust VVT-i Exhaust Crankshaft Camshaft Camshaft Cooler*1 Pins Controller Journals Controller Journals Oil Connecting Oil Secondary Hydraulic Secondary Hydraulic Chain Lash Chain Lash Pump Rods Jets Tensioner Adjusters Tensioner Adjusters Relief Valve Oil Pan *1: Models with towing package 04E1EG26C *2: Oil Control Valve
32 TOYOTA TUNDRA – NEW FEATURES Oil Pump D A compact cycloid rotor type oil pump, directly driven by the crankshaft, is used. D This oil pump uses an internal relief method which circulates relief oil to the suction passage in the oil pump. This aims to minimize oil level change in the oil pan, reduce friction, and reduce the air mixing rate in the oil. Timing Chain Cover To Cylinder Block Oil Pump Cover Crankshaft Oil Pump Rotor (Cycloid Rotor) Oil Filter From Relief Oil Oil Strainer 12DEG14I Oil Jet D 4 oil jets for cooling and lubricating the pistons are provided in the cylinder block, in the center of the right and left banks. D These oil jets contain a check valve to prevent oil from being fed when the oil pressure is low. This prevents the overall oil pressure in the engine from dropping. Oil Jet Check Valve Oil Oil Jet Cross Section Cylinder Block 12CEG09Y