tacoma16_engine

NEW FEATURES – 2GR-FKS ENGINE 69

2GR-FKS ENGINE

J DESCRIPTION

The 2GR-FKS engine is a 3.5-liter, 24-valve DOHC V6 engine. This engine uses a VVT-iW (Variable Valve
Timing-intelligent Wide) VVT-i (Variable Valve Timing-intelligent) system, DIS (Direct Ignition System),
ACIS (Acoustic Control Induction System) and ETCS-i (Electronic Throttle Control System-intelligent).
These control functions achieve improved engine performance, fuel economy, and clean emissions.

" Engine Specifications A

Engine Type 2GR-FKS

No. of Cyls. & Arrangement 6-Cylinder, V Type

Valve Mechanism 24-Valve DOHC, Chain Drive (with VVT-iW and
VVT-i)

Combustion Chamber Pentroof Type

Flow of Intake and Exhaust Gasses Cross-Flow

Fuel System SFI D-4S

Ignition System cm3 (cu. in.) DIS
Displacement 3456 (210.9)

Bore × Stroke mm (in.) 94.0 × 83.0 (3.70 × 3.27)

Compression Ratio 11.8 : 1

Max. Output (SAE-NET)* 207 kW @ 6000 rpm
(278 HP @ 6000 rpm)

Max. Torque (SAE-NET)* 359 N⋅m @ 4600 rpm
(265 ft⋅lbf @ 4600 rpm)

Type DENSO FK20HBR8 (Iridium)
Spark Plug mm (in.) 0.7 – 0.8 (0.0276 – 0.0354)

Plug Gap

Firing Order 1–2–3–4–5–6

Fuel Octane Rating 91 or higher

Emission Tailpipe California ULEVIII, SFTP
Regulation Evaporative Except California Tier2-Bin5, SFTP

LEVII, ORVR

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

70 NEW FEATURES – 2GR-FKS ENGINE

" Valve Timing A

Intake VVT-iW Exhaust VVT-i
Operation Range
Operation Range
47_ TDC

0_ : Intake Valve Opening Angle

–33_ : Exhaust Valve Opening Angle

46.5_

105_ Intake Open –33_ to 47_ BTDC
Close 105_ to 25_ ABDC
Exhaust Open 64_ to 14_ BBDC
64_ Close 0_ to 46.5_ ATDC

Intake VVT-iW 14_ Exhaust VVT-i
Operation Range 25_ BDC Operation Range

26L0EG111

NEW FEATURES – 2GR-FKS ENGINE 71

JFeatures of 2GR-FKS Engine

The 2GR-FKS 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 high-expansion cycle (Atkinson cycle) is used. f — — — f

A steel laminate type cylinder head gasket is used. f — — — —

A taper squish shape is used for combustion f — — — f
chamber.

Engine Proper A cylinder block sub-assembly made of aluminum — — f — —
alloy is used.
Valve Mechanism
Lubrication System The skirt portion of each piston has a resin coating f f — — f
Cooling System applied to reduce friction.
Intake and
Exhaust System An oil pan sub-assembly made of aluminum alloy is — f f — —
Fuel System used.

A VVT-i (Variable Valve Timing-intelligent) f — — — f
system is used.

A VVT-iW (Variable Valve Timing-intelligent f — — — f
Wide) system is used.

Hydraulic lash adjusters are used. ff—f—

A chain sub-assemblies and chain tensioner — f f f —
assemblies are used.

Roller rocker arms are used. f———f

An oil filter with a replaceable element is used. ———f—

The engine coolant is used the TOYOTA Genuine — — — f —
SLLC (Super Long Life Coolant).

A linkless type throttle body is used. ——f f—

An intake air surge tank assembly made of plastic is — — f — —
used.

A stainless steel exhaust manifold is used. ——f—f

An ultra thin-wall, high-cell density ceramic type — — — — f
TWC (Three-Way Catalytic converter) is used.

A Direct injection 4-stroke gasoline engine Superior f — — — f
version (D-4S) system is used.

Quick connectors are used to connect the fuel hose — — — f —
with the fuel pipe.

(Continued)

72 NEW FEATURES – 2GR-FKS ENGINE

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

The DIS (Direct Ignition System) makes ignition f — — f f
timing adjustment unnecessary.

Ignition System Long-reach type iridium-tipped spark plugs are f — — f f
used.
Charging System
Starting System A segment conductor type generator is used. f—f——
Serpentine Belt
Drive System A generator pulley with a one way clutch is used. f — — — f

Engine Control A PS (Planetary reduction-Segment conductor — — f — —
System motor) type starter is used.

f: Applicable A serpentine belt drive system is used. ——f f—
—: Not Applicable
MRE (Magnetic Resistance Element) type VVT f — — — —
sensors are used.

The ETCS-i (Electronic Throttle Control f — — — f
System-intelligent) is used.

An ACIS (Acoustic Control Induction System) is f — — — —
used.

An evaporative emission control system is used. — — — — f

NEW FEATURES – 2GR-FKS ENGINE 73

JEngine Proper

1. Cylinder Head Cover

D A light-weight, resin cylinder head cover has been adopted.
D An oil delivery pipe is installed inside the cylinder head cover sub-assemblies. This ensures lubrication

to the sliding parts of the roller rocker arms, improving reliability.

*1 *6
*2 *5

*3 *1
*4
26L0EG01

" Text in Illustration A

*1 Oil Delivery Pipe *2 Cylinder Head Cover Sub-assembly
RH

*3 Cylinder Head Cover Gasket *4 No. 2 Cylinder Head Cover Gasket

*5 Cylinder Head Cover Sub-assembly *6 Oil Filler Cap Sub-assembly
LH

74 NEW FEATURES – 2GR-FKS ENGINE

2. Cylinder Head Gasket
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.

AA *1
*a *c

*b 26L0EG02

" Text in Illustration A ——
*1 Shim *b for Left Bank
*a for Right Bank ——
*c A – A Cross Section ——
Engine Front

26L0EG68

NEW FEATURES – 2GR-FKS ENGINE 75

3. Cylinder Head

D The cylinder head sub-assemblies structure is simplified by separating the cam journal portion (camshaft
housing sub-assembly) from the cylinder head.

D The cylinder head sub-assemblies, which is made of aluminum, contains pentroof-type combustion
chambers. The spark plug is located in the center of the combustion chamber in order to improve the
engine’s antiknock performance.

D A taper squish combustion chamber is used to improve anti-knock performance and intake efficiency. In
addition, engine performance and fuel economy are improved.

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.

A *4
*c

*1

*2 *c
*d
*3
*5 26L0EG03
*d *b
A
*2 Spark Plug Hole
*a *4 Camshaft Housing
——
" Text in Illustration A *b A – A Cross Section
*1 Intake Valve *d Exhaust Side
*3 Exhaust Valve
*5 Taper Squish *b
*a View from Bottom Side
*c Intake Side

— REFERENCE —
*a

26L0EG112

" Text in Illustration A *b Independent Type
*a Siamese Type

76 NEW FEATURES – 2GR-FKS ENGINE

4. Cylinder Block

D The cylinder block sub-assembly is made of aluminum alloy, thus making it lightweight.
D The cylinder block sub-assembly has a bank angle of 60_, a bank offset of 36.6 mm (1.44 in.) and a bore

pitch of 105.5 mm (4.15 in.), resulting in a compact block (length and width) for its displacement.
D Installation bosses for the 2 knock control sensors are located on the inside of the left and right banks.

*a
60_

36.6 mm
(1.441 in.)

105.5 mm 26L0EG04
(4.15 in.)

" Text in Illustration A ——
*a Knock Control Sensor Boss

D A water passage has been provided between the cylinder bores. By allowing the engine coolant to flow
between the cylinder bores, this construction enables the temperature of the cylinder walls to be kept
uniform.

*a

26L0EG05

" Text in Illustration A ——
*a Water Passage

NEW FEATURES – 2GR-FKS ENGINE 77

D A compact block has been achieved by producing the thin cast-iron liners and cylinder block sub-assembly
as a unit. It is not possible to rebore a block which uses this type of liner.

D The liners are a 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
sub-assembly. The enhanced adhesion helps improve heat dissipation, resulting in a lower overall
temperature and reduced heat deformation of the cylinder bores.

*1 *2

*a

" Text in Illustration A 26L0EG06

*1 Liner *2 Cylinder Block Sub-assembly
——
*a Irregularly Shaped Outer Casting
Surface of Liner

5. Piston

D The pistons are made of aluminum alloy.
D The top of the pistons use a taper squish shape to achieve fuel combustion efficiency.
D The piston skirt is coated with resin to reduce friction losses.
D The groove of the top ring is coated with alumite to ensure abrasion resistance.
D By increasing the machining precision of the cylinder bore diameter in the cylinder block sub-assembly,

only one size piston is required.

*1 *a

" Text in Illustration A 26L0EG08

*1 Front Mark ——
*a Taper Squish Shape ——

Resin Coating Alumite Coating

26L0EG69 26L0EG70

78 NEW FEATURES – 2GR-FKS ENGINE

6. Connecting Rod and Connecting Rod Bearing

D Connecting rod sub-assemblies that have been forged for high strength are used for weight reduction.
D Knock pins are used at the mating surfaces of the connecting rod caps to minimize the shifting of the

connecting rod caps during assembly.
D Nutless-type plastic region tightening bolts (connecting rod bolts) are used on the connecting rod

sub-assemblies for a lighter design.
D Aluminum bearings are used for the connecting rod bearings.
D The connecting rod bearings are reduced in width to reduce friction. The bearing lining surface is coated

with resin to improve wear and seizure resistance.

*1 *4
*2

*a

*3 *3 26L0EG09

" Text in Illustration A

*1 Connecting Rod Sub-assembly *2 Knock Pin
*4 Connecting Rod Bearing
*3 Plastic Region Tightening Bolt ——
(Connecting Rod Bolt)

*a Resin Coating

NEW FEATURES – 2GR-FKS ENGINE 79
7. Crankshaft
D A crankshaft made of forged steel, which excels in rigidity and wear resistance, is used.
D The crankshaft has 4 main bearing journals and 5 balance weights.

*5

*1 *2 *3 *4

" Text in Illustration A 26L0EG10
*1 No. 1 Bearing Journal
*3 No. 3 Bearing Journal *2 No. 2 Bearing Journal
*5 Balance Weight *4 No. 4 Bearing Journal
Engine Front ——

26L0EG68 ——

80 NEW FEATURES – 2GR-FKS ENGINE

8. 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.
D The bearing lining surface is coated with resin to improve wear and seizure resistance.
D The upper crankshaft bearings have an oil groove around the inside circumference.
D The crankshaft bearing caps are tightened using 4 plastic region tightening bolts (crankshaft bearing cap

set bolts) for each journal. In addition, each cap is tightened laterally to improve its reliability.

*1

*6
*a

*2

*3 *4

" Text in Illustration A *5

*1 Plastic Region Tightening Bolt 26L0EG11
(Crankshaft Bearing Cap Set Bolt)
*2 Crankshaft Bearing Cap
*3 Seal Washer *4 Resin Coating
*6 Upper Crankshaft Bearing
*5 Lower Crankshaft Bearing ——

*a Oil Groove

NEW FEATURES – 2GR-FKS ENGINE 81
9. Crankshaft Pulley
The rigidity of the crankshaft pulley with its built-in torsional damper rubber reduces noise.

*1

26L0EG12

" Text in Illustration A ——
*1 Torsional Damper Rubber

10. Oil Pan

D The oil pan sub-assembly is made of aluminum alloy.
D The No. 2 oil pan sub-assembly is made of steel.
D The oil pan sub-assembly is secured to the cylinder block sub-assembly and the transmission housing to

increase rigidity.

*3

*1 *2

" Text in Illustration A 26L0EG13
*1 Oil Filter Case
*3 Oil Pan Sub-assembly *2 No. 2 Oil Pan Sub-assembly
——

82 NEW FEATURES – 2GR-FKS ENGINE

JVALVE MECHANISM

1. General
D A high-expansion cycle (Atkinson cycle) is used to improve heat efficiency.
D On the intake side, Variable Valve Timing-intelligent Wide (VVT-iW), which is provided with an

intermediate lock mechanism that optimally controls the intake camshaft (camshaft) to the valve timings
according to driving conditions, is used.
D On the exhaust side, Variable Valve Timing-intelligent (VVT-i), which optimally controls the exhaust
camshaft (No. 2 camshaft) to the valve timings according to driving conditions, is used.

" Valve Timing Variable Range A

VVT-iW (Intake) + VVT-i (Exhaust) Retard Advance Retard
Valve Lift Lock Position

Exhaust Crank Angle (CA) Intake
Retard Advance
Dual VVT-i (Reference)

Valve Lift

Crank Angle (CA) 26L0EG113

NEW FEATURES – 2GR-FKS ENGINE 83

D Each cylinder of this engine has 2 intake valves and 2 exhaust valves. Intake and exhaust efficiency is
increased due to the larger total port areas.

D This engine uses No. 1 valve rocker arm sub-assemblies with the built-in needle bearings. This reduces
the friction that occurs between the cams and the No. 1 valve rocker arm sub-assemblies that push the
valves down, thus improving fuel economy.

D Valve lash adjuster assemblies, which maintain a constant zero valve clearance through the use of oil
pressure and spring force, are used.

D The intake camshafts are driven by the crankshaft via the chain sub-assembly (primary). The exhaust
camshafts are each driven by the intake camshaft of their respective bank via a No. 2 chain sub-assembly
(secondary).

D This engine has the Dual Variable Valve Timing-intelligent Wide (Dual VVT-iW) system which controls
the intake and exhaust camshafts to provide optimal valve timing in accordance with driving conditions.
With this, lower fuel consumption, higher engine performance, and fewer exhaust emissions have been
achieved.

*3 *4 *7
*2
*5
*6

*8

*1 *9

*2

26L0EG14

" Text in Illustration A

*1 Chain Sub-assembly (Primary) *2 No. 2 Chain Sub-assembly (Secondary)

*3 No. 2 Camshaft Sub-assembly *4 No. 1 Camshaft Sub-assembly (Intake)
(Exhaust)

*5 No. 3 Camshaft Sub-assembly (Intake) *6 No. 4 Camshaft Sub-assembly
(Exhaust)

*7 No. 1 Valve Rocker Arm Sub-assembly *8 Valve Lash Adjuster Assembly

*9 Valve ——

84 NEW FEATURES – 2GR-FKS ENGINE

2. Camshaft

D The camshafts are made of cast iron alloy.
D Oil passages are provided on the intake and exhaust camshafts in order to supply engine oil to the Variable

Valve Timing-intelligent Wide (VVT-iW) system and Variable Valve Timing-intelligent (VVT-i).

D Camshaft timing gear assemblies and camshaft timing exhaust gear assemblies 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 No. 1 valve rocker arm sub-assemblies, the cam profile has been modified.
This results in increased valve lift when the valve begins to open and as it finishes closing, helping to
achieve enhanced output performance.

*4 *4 *3 *a
*1 *2 *4 *7

*a

*b *b

*5 *8
*6
*9 *4 26L0EG15

" Text in Illustration A

*1 Camshaft Timing Exhaust Gear *2 No. 2 Camshaft Sub-assembly
Assembly (Exhaust RH) (Exhaust RH)

*3 No. 1 Camshaft Sub-assembly *4 Timing Rotor
(Intake RH)

*5 Camshaft Timing Gear Assembly *6 Camshaft Timing Gear Assembly
(Intake RH) (Intake LH)

*7 No. 3 Camshaft Sub-assembly *8 No. 4 Camshaft Sub-assembly
(Intake LH) (Exhaust LH)

*9 Camshaft Timing Exhaust Gear ——
Assembly (Exhaust LH)

*a Increased Valve Lift *b Modified Profile of Camshaft Lobe

NEW FEATURES – 2GR-FKS ENGINE 85

3. Timing Chain and Chain Tensioner

D The chain sub-assembly (primary) and No. 2 chain sub-assemblies (secondary) are roller chains with a
pitch of 9.525 mm (0.375 in.).

D All chain sub-assemblies are lubricated by an oil jet.
D A chain tensioner assemblies is provided for each primary and secondary chain sub-assemblies in each

bank.
D Both types of chain tensioner assemblies use a spring and oil pressure to maintain proper chain tension

at all times. They suppress noise generated by the chain sub-assemblies.
D The chain tensioner assembly (primary) is a ratchet type with a non-return mechanism.

*12 *11 *10 *11 *16

*1

*2
*3 *5

*4

*6 *7 *4 *12
*15

*2 *8 *9 *14
*13

26L0EG16

" Text in Illustration A

*1 No. 2 Chain Tensioner Assembly *2 Ball
(Secondary RH)

*3 Main Spring *4 Plunger

*5 Ball Spring *6 No. 1 Chain Tensioner Assembly
(Primary)

*7 Spring *8 Cam Spring
*9 Cam
*11 No. 2 Chain Vibration Damper *10 Idle Sprocket Assembly
*13 Chain Tensioner Slipper
*12 No. 2 Chain Sub-assembly (Secondary)

*14 No. 1 Chain Vibration Damper

*15 Chain Sub-assembly (Primary) *16 No. 3 Chain Tensioner Assembly
(Secondary LH)

86 NEW FEATURES – 2GR-FKS ENGINE

4. Timing Chain Cover

D The timing chain cover has an integrated construction consisting of the cooling system (water pump and
water passage) and the lubrication system (oil pump and oil passage). Thus, the number of parts has been
reduced to reduce weight.

D The timing chain cover assembly has a structure which allows the installation of a cam timing oil control
solenoid assembly for VVT-iW control.

D The reinforced ribs have been optimally placed while the thickness of the timing chain cover assembly
has been reduced to achieve weight reduction and quietness.

*4

*4 *3
*2 *5

*1 *a *6 *7 26L0EG17
*b
" Text in Illustration A
*2 Water Pump Gasket
*1 Engine Water Pump Assembly *4 Timing Chain Cover
*3 Water Pump Swirl Chamber *6 Oil Pump Rotor
*5 Oil Pump Housing
*7 Oil Pump Chamber ——
*a View from Front Side *b View from Back Side

NEW FEATURES – 2GR-FKS ENGINE 87

5. Hydraulic Lash Adjuster

D The hydraulic lash adjusters, which are located at the fulcrum (pivot point) of the roller rocker arms, each
consist primarily of a plunger, plunger spring, check ball, and check ball spring.

D Both the engine oil that is supplied by the cylinder head and sub-assembly 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 is reduced.

*5 *6 *8

*7

*1 *1
*2

*3
*4

285EG22

" Text in Illustration A *2 Check Ball
*4 Plunger Spring
*1 Oil Passage *6 Hydraulic Lash Adjuster
*3 Check Ball Spring *8 Cam
*5 Plunger
*7 Roller Rocker Arm

Service Tip
Valve clearance adjustment is not necessary because hydraulic lash adjusters are used on this model.

88 NEW FEATURES – 2GR-FKS ENGINE
JLUBRICATION SYSTEM

1. 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 The Variable Valve Timing-intelligent Wide (VVT-iW) system is used. This system is operated by the

engine oil.

Oil Pump

Oil Strainer Sub-assembly 26L0EG18
Oil Filter Cap Assembly Oil Cooler Assembly*

*: Models with Oil Cooler Assembly

NEW FEATURES – 2GR-FKS ENGINE 89

" Oil Circuit A

Main Oil Hole

Oil Cylinder Head Cylinder Head Cylinder Block Cylinder Head Cylinder Head
Cooler* Sub-assembly Sub-assembly Sub-Assembly Sub-assembly Sub-assembly
(for Left Bank) (for Right Bank) (for Left Bank) (for Right Bank)

Oil Camshaft Camshaft Crankshaft Intake Intake
Filter Timing Timing Journal Camshaft Camshaft
Gear Bolt Gear Bolt Journal Journal

Relief Camshaft Camshaft Crankshaft Exhaust Exhaust
Valve Timing Timing Pins Camshaft Camshaft
Gear Bolt Gear Bolt Journal Journal
Connecting
Oil Exhaust Exhaust Rods
Pump VVT-iW VVT-iW
Controller Controller

Intake Intake Primary Oil Lash Lash
VVT-iW VVT-iW Chain Jets Adjuster Adjuster
Controller Controller Tensioner

Relief Secondly Secondly
Valve Chain Chain
Tensioner Tensioner

Oil Pan

26L0EG125

*: Models with Oil Cooler Assembly

2. 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 sub-assembly, reduce friction, and reduce the
air mixing rate in the oil.

Timing Chain Cover

Oil Pump Housing to Cylinder Block

Oil Pump Rotor to Oil Filter from Oil Strainer
(Cycloid Rotor) Oil Passage in the Oil Pump

26L0EG19

90 NEW FEATURES – 2GR-FKS ENGINE

3. Oil Jet
D Oil jets for cooling and lubricating the pistons are provided in the cylinder block sub-assembly, 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

26L0EG20

NEW FEATURES – 2GR-FKS ENGINE 91

4. Oil Filter

D An oil filter with a replaceable element is used. The element uses a high-performance filter paper to
improve filtration performance. It is also combustible for environmental protection.

D A plastic filter cap is used to extend its life.

Oil Filter Case

Element
Filter Cap

Drain Bolt

26L0EG21

92 NEW FEATURES – 2GR-FKS ENGINE

JCOOLING SYSTEM

1. General

D The cooling system is a pressurized, forced-circulation type. The reservoir tank is not pressurized.
D A thermostat valve is located in the water inlet housing to maintain suitable temperature distribution in

the cooling system.
D The engine coolant uses TOYOTA genuine SLLC (Super Long Life Coolant).

from Throttle Body with Motor Assembly from Heater
to Heater

to Radiator Assembly Thermostat

to Throttle Body with 26L0EG22
Motor Assembly

from Radiator Assembly
Oil Cooler Assembly*

*: Models with Oil Cooler Assembly

NEW FEATURES – 2GR-FKS ENGINE 93

" Water Circuit A

Outlet Throttle Body with Motor Assembly
Thermostat Bypass Pipe
Inlet
Heater Return Pipe

Air Bleeder Plug Heater

Cylinder Head
Sub-assembly

Cylinder Block
Sub-assembly

Engine Water Pump
Assembly

Radiator Assembly

Oil Cooler 26L0EG126
Assembly*

*: Models with Oil Cooler Assembly

2. Water Pump

The engine water pump assembly has two volute chambers, and circulates coolant uniformly to the left and
right banks of the cylinder block sub-assembly.

Timing Chain Cover from Water Inlet Housing
Rotor

Water Pump Gasket

View from Back Side

Engine Water Pump Volume Chambers Cross Section
Assembly

26L0EG23

94 NEW FEATURES – 2GR-FKS ENGINE

3. TOYOTA Genuine SLLC

TOYOTA genuine SLLC (Super Long Life Coolant) is used. The maintenance interval is as shown in the
table below:

Type First Time TOYOTA Genuine SLLC
Maintenance Intervals Subsequent 100,000 miles (160,000 km)
Color Every 50,000 miles (80,000 km)

Pink

D SLLC is pre-mixed (50% coolant and 50% deionized water), so no dilution is needed when adding or
replacing SLLC in the vehicle.

D If LLC is mixed with SLLC, the interval for LLC (every 25,000 miles (U.S.A.), 32,000 km (Canada) or
24 months whichever come first) should be used.

D You can also apply the new maintenance interval (every 50,000 miles/80,000 km) to vehicles initially
filled with LLC (red-colored), if you use SLLC (pink-colored) for the engine coolant change.

4. Thermostat 85_C to 89_C (185_F to 192_F)
" Specifications A

Thermostat Opening Temperature

NEW FEATURES – 2GR-FKS ENGINE 95

JINTAKE AND EXHAUST SYSTEM

1. General

D A link-less type throttle body with motor assembly is used which realizes excellent throttle control.
D The intake air surge tank assembly made of plastic is used.
D Stainless steel exhaust manifolds are used for weight reduction.
D The ETCS-i (Electronic Throttle Control System-intelligent) is used to ensure excellent throttle control

in all operating ranges. For details, see page 145.
D The ACIS (Acoustic Control Induction System) is used to improve the engine performance in all speed

ranges. For details, see page 158.
D TWCs (Three-way Catalytic converters) are provided in the exhaust manifold sub-assembly of each bank,

front exhaust pipe assembly and also in the No. 2 front exhaust pipe assembly.

Intake Air Surge Front Exhaust Pipe
Tank Assembly Assembly

No. 1 Air Exhaust Tail Pipe
Cleaner Hose Assembly

Air Cleaner
Assembly

Center Exhaust
Pipe Assembly
No. 2 Front Exhaust
Pipe Assembly

Exhaust Manifold Exhaust Manifold
Sub-assembly RH Sub-assembly LH

Throttle Body with
Motor Assembly

Intake Manifold

26L0EG24

96 NEW FEATURES – 2GR-FKS ENGINE

2. Air Cleaner
D A paper type air cleaner filter element sub-assembly is used.
D A charcoal filter, which absorbs the HC that accumulates in the intake system when the engine is stopped,

is used in the air cleaner case in order to reduce evaporative emissions. This filter is maintenance-free
D A resonator is provided in the No. 1 air cleaner hose, helping to reduce intake noise.

Charcoal Filter

Resonator

Air Cleaner Cap

Air Cleaner Filter Element No. 1 Air Cleaner
Sub-assembly Hose

Air Cleaner Inlet Air Cleaner Case
Sub-assembly Sub-assembly

26L0EG25

NEW FEATURES – 2GR-FKS ENGINE 97

3. Throttle Body

D A link-less type throttle body with motor assembly in which the throttle position sensor and the throttle
control motor are integrated is used. If realizes excellent throttle valve control. The throttle control motor
uses a DC motor with excellent response and minimal power consumption. The ECM performs duty ratio
control of the direction and the amperage of the current that follows to the throttle control motor in order
to regulate the throttle valve angle.

Throttle Position
Sensor

Throttle Control Motor 26L0EG26

4. Intake Air Chamber
D The intake air surge tank assembly is made of plastics to realize a lightweight construction.
D The intake air surge tank assembly consists of an upper and lower section and contains an intake air control

valve. This valve is activated by ACIS (Acoustic Control Induction System) and is used to alter the intake
pipe length to improve the engine performance in all engine speed ranges.
D The ACIS actuator uses an electric actuator.

Intake Air Surge Tank Assembly

ACIS Actuator

26L0EG27

98 NEW FEATURES – 2GR-FKS ENGINE

5. Intake Manifold
D A lightweight aluminum alloy is used for the intake manifold.
D The intake manifold gaskets have a rubber coating applied to their surfaces. They provide superior

durability.

Intake Manifold

Rubber Coating

A A – A Cross Section
Intake Manifold Gasket
A
26L0EG28

6. Exhaust Manifold

D A stainless steel exhaust manifolds with an integrated TWC (Three-Way Catalytic converter) is used for
warm-up of the TWC and for weight reduction.

D An ultra-thin wall, high-cell density, ceramic type TWC is used. One of this type of TWC is incorporated
into the exhaust manifold for each of the right and left banks.

D This TWC enable an improvement in the reduction of exhaust emission by optimizing the cell density and
the cell wall thickness.

Exhaust Manifold
Sub-assembly RH

Exhaust Manifold to
Head Gasket

TWC

Exhaust Manifold TWC
to Head Gasket
26L0EG29
Exhaust Manifold
Sub-assembly LH

NEW FEATURES – 2GR-FKS ENGINE 99

7. Exhaust Pipe

D The exhaust pipes are made of stainless steel for improved rust resistance.
D A thin-wall, ceramic type TWC is used.
D A main muffler is used to ensure engine performance and reduce exhaust noise.
D A ball joint is used to join the front exhaust pipe assembly and center exhaust pipe assembly. As a result,

in-vehicle sound has been muffled, vibration has been minimized, and weight reduction has been realized.

Gasket Compression Spring
Flange Bolt

Exhaust Tail Pipe Assembly

Ball Joint

Front Exhaust
Pipe Assembly

Center Exhaust
Pipe Assembly

TWC

TWC No. 2 Front Exhaust
Pipe Assembly
26L0EG30

100 NEW FEATURES – 2GR-FKS ENGINE

JFUEL SYSTEM

1. General

D The 2GR-FKS engine uses a Direct injection 4-stroke gasoline engine Superior version (D-4S) system,
which has both direct and port type fuel injection. Fuel sent from the fuel pump (low pressure) in the fuel
tank assembly is delivered to the low-pressure and high-pressure fuel systems. The fuel delivered to the
low-pressure fuel system is injected from the fuel injector assembly (for port injection) to the intake port.
The fuel delivered to the high-pressure fuel system is pressurized by the fuel pump assembly (high
pressure) and injected from the fuel injector assembly (for direct injection) to the combustion chamber.
The system achieves improved engine performance, fuel economy and clean emissions.

D The direct injection system mainly consists of the fuel pump assembly (high pressure), fuel delivery pipe
(for direct injection) and fuel injector assembly (for direct injection). In this system, the ECM controls the
fuel pump assembly (high pressure) and fuel injector assembly (for direct injection) based on signals from
various sensors, thus optimally controlling fuel pressure, injection volume and injection timing.

D The port injection system mainly consists of the fuel pump (low pressure), fuel delivery pipe (for port
injection) and fuel injector assembly (for port injection). In this system, the ECM controls the fuel pump
assembly (low pressure) and fuel injector assembly (for port injection) based on signals from various
sensors, thus optimally controlling injection volume and timing.

D The low-pressure fuel system uses the fuel pressure sensor (for low pressure) to perform variable fuel
pressure control. Low fuel consumption is achieved by reducing the power consumption of the fuel pump
(low pressure), which optimally controls the fuel pressure according to the driving conditions.

D Fuel pressure control for the high-pressure fuel system is performed via the spill control valve installed
in the fuel pump assembly (high pressure).

D A fuel cut control is used to stop the fuel pump (for low pressure) when any of the Supplemental Restraint
System (SRS) airbags are deployed.

2. D-4S System

D The Direct injection 4-stroke gasoline engine Superior version (D-4S) system is based on 2 types of fuel
injection systems: the direct injection system and the port injection system. Fuel sent from the fuel tank
assembly is delivered to the low-pressure and high-pressure fuel systems. The fuel delivered to the
low-pressure fuel system is injected from the fuel injector assembly (for port injection) to the intake port.
The fuel delivered to the high-pressure fuel system is pressurized by the fuel pump assembly (for high
pressure) and injected from the fuel injector assembly (for direct injection) to the combustion chamber.

D The direct injection system mainly consists of the fuel pump assembly (for high pressure), fuel delivery
pipe sub-assembly (for direct injection) and fuel injector assembly (for direct injection). In this system,
the ECM controls the fuel pump assembly (for high pressure) and fuel injector assembly (for direct
injection) based on signals from various sensors, thus optimally controlling fuel pressure, injection
volume, and injection timing.

D The port injection system mainly consists of the fuel pump assembly (for low pressure), fuel delivery pipe
sub-assembly (for port injection), and fuel injector assembly (for port injection). In this system, the ECM
controls the fuel pump assembly (low pressure) and fuel injector assembly (for port injection) based on
signals from various sensors, thus optimally controlling injection volume and timing.

NEW FEATURES – 2GR-FKS ENGINE 101

" System Diagram A

Fuel Pressure Sensor
(for Low Pressure)

Injector Drive Signal

Fuel Injector Assembly
(for Port Injection)

Injector Drive Signal

Fuel Pump Drive ECM Fuel Injector Assembly
(for Direct Injection)
Fuel Pump Request Signal
Control ECU Injector Drive Signal

Fuel Pump Fuel Pressure Sensor (for High Pressure)
Drive Signal Fuel Injector Assembly (for Port Injection)

Injector Drive Signal

Low-pressure Fuel Pipe High-pressure Fuel Pipe

Fuel Pump Assembly (for High Pressure)

Spill Control Valve Spill Control Valve
Drive Signal

Fuel Main Valve Fuel Pressure Check Valve
Assembly Pulsation Damper
Relief Valve
Fuel Pressure Fuel Pump Lifter
Regulator Assembly Assembly
(Relief Valve)

Fuel Pump Assembly Fuel Filter Exhaust Camshaft
(for Low Pressure) Assembly (Cam to Drive Fuel Pump)

Fuel Tank Assembly 26L0EG75

102 NEW FEATURES – 2GR-FKS ENGINE

3. Layout of Main Components

Fuel Pump Assembly Fuel Delivery Pipe Canister
(for High Pressure) Sub-assembly
(for Direct Injection)
Fuel Delivery Pipe
Sub-assembly
(for Port Injection)

Fuel Injector Assembly Fuel Tank Assembly
(for Port Injection)
Fuel Suction with Pump
Fuel Injector Assembly and Gage Tube Assembly
(for Direct Injection) D Fuel Pump Assembly (for Low Pressure)
D Fuel Filter Assembly
D Fuel Main Valve Assembly
D Fuel Pressure Regulator Assembly
D Fuel Sender Gauge Assembly

26L0EG31

NEW FEATURES – 2GR-FKS ENGINE 103

4. Function of Main Components

The D-4S system has the following components and functions:

Component Function
Fuel Pump Assembly (for Low Pressure)
The newly adopted full-demand variable fuel
Fuel Pump Assembly (for High Pressure) pressure system controls fuel pressure in a range
between 300 and 530 kPa.
Spill Control Valve
Fuel Pressure Pulsation Damper Increases the pressure of the fuel from the fuel
Fuel Delivery Pipe Sub-assembly pump assembly (for low pressure) to a pressure of
(for Port Injection) 2 to 20 MPa and sends it to the fuel delivery pipe
Fuel Delivery Pipe Sub-assembly sub-assembly (for direct injection).
(for Direct Injection)
Fuel Pressure Sensor (for Low Pressure) Closes and opens the fuel flow path to the
Fuel Pressure Sensor (for High Pressure) high-pressure fuel system in accordance with
Fuel Injector Assembly (for Port Injection) signals from the ECM.

Fuel Injector Assembly (for Direct Injection) Reduces fuel pressure fluctuation (pulsation) and
noise.
Fuel Pump Control ECU
Delivers the low-pressure fuel to the fuel injector
ECM assembly (for port injection).

Delivers the high-pressure fuel to the fuel injector
assembly (for direct injection).

Detects a fuel pressure in the low pressure fuel pipe,
and output it to the ECM.

Detects a fuel pressure in the high pressure fuel
pipe, and output it to the ECM.

Fuel is injected for an optimum injection period
calculated by the ECM in accordance with the fuel
pressure detected by the fuel pressure sensor.

Injects a calculated (by the ECM) quantity of 2 to
20 MPa (high pressure) fuel directly into the
combustion chamber.

Receives signals, output from the ECM, requesting
the fuel pump to be driven, and controls the fuel
pump (low pressure) in accordance with the
received signals.

D Calculates low pressure fuel demand based on
vehicle state and the signals sent from various
sensors, and outputs signals requesting the fuel
pump to be driven to the fuel pump control ECU.

D Depending on the vehicle condition, and based
on signals from various sensors, the ECM
calculates the optimal injection timing and
volume, and controls the fuel injector assembly
(for direct injection) and fuel pump assembly
(for high pressure).

104 NEW FEATURES – 2GR-FKS ENGINE

5. Function

D The Direct injection 4-stroke gasoline engine Superior version (D-4S) system has both direct type fuel
injection, which directly injects high-pressure fuel into the combustion chamber, and port type fuel
injection, which injects fuel into the intake port. The system optimally controls the fuel injectors for direct
injection and port injection according to engine load.

D In low to medium engine load ranges, both direct type and port type fuel injections are used together or
one of them is used to create homogeneous mixed air, thus contributing to stable combustions. With this,
the system achieves low fuel consumption and low emissions. In addition, in high engine load ranges, only
the direct type fuel injection is used to cool down the intake air with the chilling effect of vapors in the
fuel which is injected into the cylinder, improving charging efficiency and anti-knock properties.

D Immediately after the engine is started in cold state, the fuel injector assembly on the port side is selected
for the injection aiming at homogenizing the mixture in the combustion chamber. Next, the fuel injector
assembly on the cylinder injection side performs fuel injection during the compression process in order
to stratify the mixture layers around the spark plug. This formation not only enables a substantial
retardation of ignition timing but also raises the exhaust gas temperature, which facilitates the warm-up
of the catalyst following a cold start.

D Slit-nozzle type injectors, which have 1 slit injection orifices, are used as fuel injectors for direct injection.
The fuel atomized by the high-pressure 1 slit fuel injector assembly is injected into the combustion
chamber via the 1 slit, spreading in a fan shaped pattern and winding up a mass of the air. Highly
pressurized and atomized fuel spreads through the whole combustion chamber by its own energy, without
depending on the air stream, then is mixed with the intake air, achieving the ideal combustion in all driving
ranges

Fuel Injector Assembly
(for Port Injection)

Fuel Injector Assembly
(for Direct Injection)

26L0EG76

NEW FEATURES – 2GR-FKS ENGINE 105

6. Fuel Returnless System

A fuel returnless system is used to reduce evaporative emissions. As shown below, by integrating the fuel
filter assembly, fuel pressure regulator assembly and fuel pump assembly (for low pressure), it is possible
to discontinue the return of fuel from the engine area, thus preventing temperature rise inside the fuel tank
assembly. This reduces the generation of evaporative emissions in the fuel tank assembly.

to Fuel Pump Assembly
(for High Pressure)

Fuel Main Fuel Pressure Regulator
Valve Assembly (Relief Valve)
Fuel Injector Assembly Assembly
(for Port Injection)

Fuel Tank
Assembly

Fuel Delivery Pipe Fuel Filter Fuel Pump Assembly
Sub-assembly Assembly (for Low Pressure)
(for Port Injection)
26L0EG77

7. Fuel Tank Assembly

D A multi-layer plastic fuel tank assembly is used. The multiplex layered plastic fuel tank assembly consists
of six layers of four types of materials, and one of those is a recyclable material to address environmental
concerns.

D Fuel drain marks have been provided at the lowest position of the fuel tank assembly. When dismantling
(scrapping) the vehicle, drain fuel by drilling a hole at the drain mark.

Fuel Drain Mark

View from Bottom Side 26L0EG35

106 NEW FEATURES – 2GR-FKS ENGINE

8. Fuel Pump

D A compact fuel pump assembly (for low pressure) is used. Its basic components are a fuel pump, a fuel
filter assembly, a fuel main valve assembly, a fuel pressure regulator assembly and a fuel sender gauge
assembly.

D The fuel pump assembly (for low pressure) is located in the fuel tank assembly. This fuel pump pressurizes
the fuel from the fuel tank assembly and sends the fuel to the high-pressure and low-pressure fuel systems.

Fuel Filter Fuel Pump Assembly
Assembly (for Low Pressure)

Fuel Main Valve Fuel Sender
Assembly Gauge Assembly

Fuel Pressure Regulator 26L0EG36
Assembly (Relief Valve)

NEW FEATURES – 2GR-FKS ENGINE 107

9. Fuel Pump (for High Pressure)

D The fuel pump assembly (for high pressure) consists of a plunger, spill control valve and check valve. A
fuel pressure pulsation damper assembly is also installed at the fuel inlet.

D The plunger is moved up and down by a lobe that is located at the rear end of the exhaust camshaft on the
right bank of the engine. This lobe causes 3 strokes of the pump piston to occur for each camshaft
revolution (3 protrusions exist 120 degrees from each other on the same camshaft “lobe”).

D The pressure of highly pressurized fuel is adjusted between 2.0 to 20 MPa in accordance with the vehicle
driving conditions, reducing friction loss.

D A spill control valve is used to control the pump discharge pressure. The spill control valve is located in
the inlet passage of the fuel pump assembly (for high pressure).

D A check valve is present in the outlet of the fuel pump assembly (for high pressure). As the pressure in
the outlet of the pump rises and becomes high enough to push the check valve off its seat, fuel will begin
to flow to the fuel delivery pipe sub-assembly (for direct injection) (minimum pressure to open the check
valve is 60 kPa).

Low-pressure Fuel (from Spill Control Valve Fuel Delivery Pipe Sub-assembly
Fuel Pump Assembly (for Direct Injection) (Bank 1)
(for Low Pressure))

Fuel Injector Assembly
(for Direct Injection)

Plunger

High-pressure Fuel (to Fuel

Delivery Pipe Sub-assembly Fuel Pressure Sensor
(for Direct Injection) (Bank 1) Fuel Delivery Pipe Sub-assembly (for High Pressure)
(for Direct Injection) (Bank 2)
Fuel Pump Assembly

(for High Pressure) Fuel Pump Assembly (for High Pressure)
Spill Control Valve
Fuel Pressure
Pulsation Damper

to Fuel Injector Assembly Check Valve
(for Port Injection)

Fuel Main Valve Fuel Pressure
Assembly Regulator Assembly
(Relief Valve)

Fuel Tank Relief Valve
Assembly
Fuel Pump Lifter
Assembly

Fuel Filter Fuel Pump Assembly Exhaust Camshaft
Assembly (for Low Pressure) (Cam to Drive Fuel Pump)

26L0EG37

108 NEW FEATURES – 2GR-FKS ENGINE

Operation

D During the intake portion of the pump cycle, the spill control valve is opened, and the pump plunger
(piston) is moved downward by spring force. This allows fuel to be drawn into the cylinder of the pump.
If the spill control valve has not been closed yet, when the cam forces the plunger to move upward, the
fuel in the pump cylinder (this fuel is not pressurized) will be pushed back to the pump inlet (fuel tank
side).

D In order to close the spill control valve as the piston is moving upward, the ECM sends a signal to the
valve. When the spill control valve is closed and the plunger is moving upward, the pressure in the pump
cylinder will rise. As this pressure rises above 60 kPa (or the pressure of the delivery pipe, whichever
is higher), the fuel will begin to flow to the fuel delivery pipe sub-assembly (for direct injection). The
ECM calculates the target fuel pressure based on driving conditions. The ECM controls the pressure by
operating the spill control valve. The timing and duration of the spill control valve closing are varied to
cause the pump pressure to meet the target pressure.

Pressure Rise Suction Pressure Rise
Inactive
Plunger Lift

Spill Control
Valve

Valve Closed Valve Open Valve Closing

Timing Control to Fuel Delivery
Pipe Sub-assembly
Fuel Pump Assembly (for Direct Injection)

(for High Pressure) Spill Control Valve Check Valve

Plunger

Fuel Pump Lifter Exhaust Camshaft
Assembly Lobe (3 peaks)

Suction Inactive Pressure Increase

from Fuel Delivery
Pipe Sub-assembly
(for Direct Injection)

Relief Valve

Relief 26L0EG78

NEW FEATURES – 2GR-FKS ENGINE 109

10. Fuel Delivery Pipe (for Direct Injection)

D An iron fuel delivery pipe sub-assembly (for direction injection) is used.
D A fuel pressure sensor (for high pressure) is installed to the fuel delivery pipe (for direct injection).
D An injector clamp is used for the installation area of the fuel injector assembly (for direct injection). The

injector clamp constantly pushes the fuel injector assembly (for direct injection) by the force of the spring
to prevent the fuel injector assembly (for direct injection) from moving when fuel pressure is applied to
the fuel injector assembly (for direct injection) while starting the engine with low fuel pressure. As a result,
vibration and noise are reduced while at the same time airtightness is increased.
D A metal touch taper seal is used for the fuel pressure sensor (for high pressure) and fuel pipe (for high
pressure) fastener.

No. 3 Fuel Pipe Assembly

No. 2 Fuel Pipe
Assembly

Fuel Delivery Pipe Sub-assembly
(for Direct Injection) (Bank 1)

Fuel Pressure Sensor
(for High Pressure)

Injector Clamp Fuel Delivery Pipe Sub-assembly
(for Direct Injection) (Bank 2)
Fuel Injector Assembly
(for Direct Injection) 26L0EG38

110 NEW FEATURES – 2GR-FKS ENGINE

11. Fuel Delivery Pipe (for Port Injection)

D A pressed fuel delivery pipe sub-assembly (for port injection), whose walls create a damping effect on fuel
pressure vibrations (pulses) that occur when the fuel injector assembly (for port injection) injects fuel, is
used. As a result, the fuel pressure pulsation damper was able to be discontinued, reducing the number of
parts while achieving weight and size reduction.

D A fuel pressure sensor (for low pressure ) is installed to the fuel delivery pipe sub-assembly (for port
injection).

D A metal touch taper seal is used for the fuel pressure sensor assembly fastener.

Fuel Delivery Pipe Sub-assembly Fuel Pressure Sensor
(for Port Injection) (for Low Pressure)

Fuel Injector Assembly 26L0EG39
(for Port Injection)

NEW FEATURES – 2GR-FKS ENGINE 111

12. Fuel Injector (for Direct Injection)

D A 1-hole type high pressure slit nozzle fuel injector assembly (for direct injection), which has 1 injection
hole shaped like a slit, is used.

D The use of this fuel injector assembly (for direct injection) causes the fuel to become highly atomized and
spread over a wide fan-shaped area. At the same time, the fuel is mixed with a large amount of air and
injected into the combustion chamber. As a result, fuel injection dissipation performance is improved to
achieve a homogeneous air-fuel mixture, high performance and high engine output.

D An O-ring and backup ring* are used in the fuel injector assembly (for direct injection). As a result, the
transmission of operation noise from the fuel injector assembly (for direct injection) is reduced to improve
quietness and ensure fastener airtightness.

NOTICE:
*: The backup ring is installed to securely support the rubber O-ring, which is subjected to high

pressures. Take care to install the backup ring in the correct direction at the correct installation
position.

O-ring
Backup Ring

Insulator

Injection Hole

Teflon Sealant 26L0EG40

Fuel Injector Assembly (for Direct Injection)
Cross Section

112 NEW FEATURES – 2GR-FKS ENGINE

13. Fuel Injector (for Port Injection)
A 12-hole long nozzle type fuel injector assembly (for port injection) is used. As a result, low fuel
consumption and low emissions are achieved by optimizing the intake airflow inside the intake port.

Injection Hole

Fuel Injector Assembly (for Port Injection) 26L0EG41
Cross Section

NEW FEATURES – 2GR-FKS ENGINE 113

JIGNITION SYSTEM

1. General

A DIS (Direct Ignition System) is used. The DIS improves ignition timing accuracy, reduces high-voltage
loss, and enhances the overall reliability of the ignition system by eliminating the need for a distributor. The
DIS is an independent ignition system which has 1 ignition coil assembly (with igniter) for each cylinder.

VVT Sensors from No. 1 Cylinder
Ignition Switch No. 3 Cylinder
Crank Position IGT1 No. 5 Cylinder
Sensor
IGT3 No. 2 Cylinder
Various Sensors No. 4 Cylinder
IGT5 No. 6 Cylinder

IGF1 26L0EG71
ECM

IGT2

IGT4

IGT6

IGF2
Ignition Coil Assembly
(with Igniter)

2. Ignition Coil

The DIS provides 6 ignition coils, for each cylinder. The Spark plug caps, which provide contact to spark
plugs, are integrated with the ignition coil assembly. Also, an igniter is enclosed to simplify the system.

Ignition Coil Assembly

26L0EG42

114 NEW FEATURES – 2GR-FKS ENGINE

3. Spark Plug

D Long-reach type spark plugs are used. This type of spark plugs allows the area of the cylinder head
sub-assembly that receive the spark plugs to be made thick. Thus, the water jacket can be extended near
the combustion chamber, which contributes to cooling performance.

D The triple ground electrode type iridium-tipped spark plugs are used to achieve a 96000 km (60000 miles)
maintenance interval. By making the tip of the electrode out of iridium, it is possible to achieve superior
ignition performance and durability when compared to platinum-tipped spark plugs, Furthermore, 2
ground electrodes have been added to further enhance ignitability, wear resistance, and fouling resistance.

Long-reach

Iridium Tip

Platinum Tip 26L0EG72

" Specifications A mm (in.) FK20HBR8
0.7 – 0.8 (0.028 – 0.031)
DENSO
Plug Gap

NEW FEATURES – 2GR-FKS ENGINE 115

JCHARGING SYSTEM

1. General

D A compact and lightweight segment conductor type generator assembly is used. This type of generator
generates a high amperage output in a highly efficient manner.

D This generator uses a joined segment conductor system, in which multiple segment conductors are welded
together at the starter. 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.

Segment Segment Stator Stator Conductor
Stator Conductor Stator Conductor Wire
Conductor Wire

A B
Joined
A – A Cross B – B Cross
B Wiring System Section
Joined Segment Section
A Conductor System Conventional Type Generator

Segment Conductor Type Generator 206EG41

206EG40

Stator

Segment Conductor
Cross Section

Stator of Segment Conductor Type Generator 206EG42

116 NEW FEATURES – 2GR-FKS ENGINE

" Specifications A

Models with Automatic Transmission:

Type CSC1
12
Rated Voltage V 130

Rated Output A 1,300

Initial Output Starting Speed rpm Max.

Models with Manual Transmission:

Type CSC0 CSC1*
12 12
Rated Voltage V 100 130

Rated Output A 1,300 1,300

Initial Output Starting Speed rpm Max. B

*: Models with Towing Package

" Wiring Diagram A

Rectifier Generator
Rectifier

Stator Regulator LIN ECM

Rotor

E

26L0EG73

NEW FEATURES – 2GR-FKS ENGINE 117

2. Dual Winding System

A dual winding is used. This system consists of two sets of three-phase windings whose phase 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 generator load is increased). This system significantly suppresses noise at the source
(generator). 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 dose not
cancel itself out, due to the use of separate rectifiers. The opposite polarities that are generated can be seen
below.

30_

BA C

Two Sets of Three-Phase Windings Three-Phase Windings
Staggered 30_ C

AB Single Windings
Dual Windings

Electromagnetic pulsation (Magnetic Noise) 26L0EG74

118 NEW FEATURES – 2GR-FKS ENGINE

JSTARTING SYSTEM
General

An RA (Reduction Armature) type starter assembly is used.

" Specifications A

Type RA1.4

Length*1 mm (in.) 153.1 (6.0)

Weight g (lb) 3800 (8.4)

Rated Voltage V 12

Rated Output kW 1.4

Rotational Direction*2 Clockwise

*1: Length from the mounted area to the rear end of the starter assembly.
*2: Viewed from pinion side.