Toyota Corolla Verso 2.2 D-4D

Dynamic versatility

September 21, 2005 6:23 AM
Filed Under: Japanese, Toyota

Press Release

Dynamic versatility

 

At a glance:

 

Toyota Corolla Verso: Dynamic versatility

 

The Toyota Corolla Verso is a challenge to the way the consumer view cars in this segment. The old notion that practicality should automatically mean pragmatic and "boxy" design has been challenged with this car. "Solid, sporty, urban and dynamic" are words which best describe the Corolla Verso.

 

For a compact MPV, the Toyota Corolla Verso offers outstanding interior space and a class­leading storage area, thanks to clever packaging. The car is in fact packed with innovative design solutions allowing for seven people to sit comfortably in this car. Thanks to Toyota's Easy Flat-7 systemTM, the new 7-seater Corolla Verso is the only MPV in the world that allows for all five rear seats to be folded flat. Added to this, the folding system is the easiest to operate in this segment.

 

The Toyota Corolla Verso is one of the top players in its segment when it comes to safety. The car features Minimal Intrusion Cabin System (MICS) -an impact absorbing structure that helps to reduce impact in the event of a collision- , and the Corolla Verso lives up to Toyota's reputation for safety, having won a maximum five-star rating by Euro NCAP, as well as an additional four stars for child safety. The car features some segment-firsts such as the innovative Cornering Assist Monitor (CAM), which helps the driver see around blind corners and a segment-first knee airbag.

 

Today, Toyota adds a new Luna Pack to the Corolla Verso range. This has been positioned in the mid-range between the Terra and Sol grades. The D-4D 180 diesel comes with a new Premium active pack which includes a complete sporty and premium package including specifications such as 17" alloy wheels, privacy glass, premium trim.

 

Thanks to its new engine range, Toyota aims to sell over 95,000 units of the Corolla Verso this year and to increase its segment share from 4.6% to 6.2%.

 

The 2.2 D-4D diesel engine range

 

The Corolla Verso joins the Avensis in becoming the second Toyota model to be fitted with the clean power 2.2 D-4D diesel engine. This, in addition to the availability of a 136 DIN hp version (D-4D 135), represents a significant step forward for Toyota in the C-MPV segment. The D-4D 135 is aimed at the heart of the C-MPV segment while the unbeatable and super­green, yet powerful, Clean Power 177 DIN hp, which will answer the needs of the more "enthusiastic" Corolla Verso drivers.

 

The 177 DIN hp 2.2 D-4D Clean Power with Toyota D-CAT, in particular, allows the Corolla Verso to truly express its driving potential. By offering superior handling performance, a commanding driving position and smooth torque delivery, the engine really does make driving the Corolla Verso an entirely pleasurable experience.

 

Both the D-4D 135 and D-4D 180 diesel engines have been developed using an all-aluminium body. The reduction in weight ensures a substantial decrease in fuel consumption and therefore harmful emissions. The choice of materials also helps with the vehicle's driving dynamics through more favourable front/rear weight distribution.

 

Toyota Computer Controlled System (TCCS) has been adopted. It helps achieve high performance whilst at the same time delivering lower fuel consumption. TCCS controls fuel injection, injector timing, Idle Speed Control (ISC), fuel pressure, glow relay, EGR and air conditioning cut.

 

A new intercooler has been installed. It features a heat exchange area eight times bigger than its predecessor. As a result, heat exchange efficiency has risen from 68% to 90%. This plays a crucial role in improving the volumetric efficiency and, consequently, performance.

 

The new 2.2 D-4D engine family is produced at Toyota Motor Industries Poland (TMIP), the main Toyota's European diesel manufacturing facility. The plant is a showcase for Toyota's on-going commitment to provide its European customers with the best diesel engines on the market.

D-4D 180: Corolla Verso flagship engine

 

Driving pleasure combined with practical solutions housed in an environmentally friendly vehicle best describe the Toyota Corolla Verso. This fusion has been made possible with the introduction of the ultra-clean, quiet and frugal 177 DIN hp 2.2 D-4D Clean Power with D-CAT engine to the car.

 

This unit is the first true high-power diesel in the C-MPV segment. The engine delivers an impressive 400 Nm of torque at 2,000 rpm, giving the Corolla Verso a sporty yet smooth feel. As well as being practical and safe, this car sprints from 0-100 km/h in just 9.0 seconds, before reaching a top speed of 205 km/h. Surprisingly, fuel consumption has been kept to an absolute minimum of 6.6 L/100km in combined cycle.

 

This is the first time in this segment that piezoelectric technology has been used. As a result, larger volumes of fuel can be injected in a shorter time than was possible with conventional injectors.

 

This in turn leads to greater fuel atomisation and more precise injection timing. Toyota’s piezoelectric common-rail system produces the highest injection pressure (1,800 bar) and the highest number of injections per cycle (5 in total) among systems of this type.

 

At 15.8:1, the unit boasts the segment’s lowest compression ratio. The lower compression ratio means the engine needs less effort to compress the mixture. This in turn results in higher efficiency, better performance and lower fuel consumption.

 

The D-4D 180 has been equipped with the latest Toyota-engineered ceramic glow plugs. Few materials have greater heat-resistance than ceramics. Its ability to withstand much higher temperatures allows the Toyota ceramic glow plug to maintain the same efficiency rates for a much longer period than conventional metallic glow plugs would allow. This is an obvious advantage when it comes to durability. Furthermore, the thermal conductivity of ceramics far exceeds that of metals. Therefore, the ceramic glow plugs are able to reach the ideal temperature quicker than metallic ones. This leads to more rapid cold starts at lower air temperature.

 

Thanks to Toyota D-CAT, the D-4D 180 is the cleanest diesel in its class (for combined NOx and PM emissions). At the heart of the Toyota D-CAT is the Diesel Particulate NOx Reduction system (DPNR). This is another pioneering technology by Toyota. The system uses reduced PM, NOx, HC and CO at the same time.

 

The catalyst features a highly absorbent ceramic filter mounted close to the exhaust manifold. A simple oxidation catalytic converter has been placed further downstream in the exhaust system.

 

D-4D 135 : At the heart of the C-MPV market

 

The 116 DIN hp 2.0 D-4D Toyota Corolla Verso is replaced by a smoother and more powerful 136 DIN hp 2.2 D-4D diesel engine that promises a more complete ride.

 

The D-4D 135 is nippy, accelerating to 100 km/h in a mere 10.0 seconds, a respectable value for a C-MPV segment car. At 2000 rpm, 310 Nm of torque kicks in, ensuring the Corolla Verso (in spite of its family proportions) offers the driver smooth overtaking capacity.

 

The evolved engine offers more power and torque, better performance, and at the same time lower fuel consumption and greener emissions standards. The 136 DIN hp engine lends itself perfectly to this C segment MPV.

New 6-speed manual transmission: Refined, fuel-efficient and compact

 

Both derivatives of the 2.2 D-4D diesel engines in the Corolla Verso range come with Toyota’s new 6-speed manual transmission system which boasts smooth, quick and precise gear­change.

 

A multi-cone synchroniser from first to fourth gears, which requires less force to manoeuvre, has contributed to the sense of smooth and more precise gear-shifting. The gearbox uses a slide ball-bearing in the select lever shaft and fork shaft for high shift efficiency as well as a shift-guide plate to decrease the amount of free play after shift. The re-shaped mass damper also improves shift smoothness.

 

With its exceptionally compact structure, a mere 384 mm in length, it beats all other 6-speed transmissions of identical or even inferior torque capacity. The use of a 3-axis construction has allowed for a 17% reduction in length, compared to the normal 2-axis configuration.

 

Fuel consumption has been reduced by 1%, thanks to the lowest viscosity oil available today for manual transmissions. Adoption of an oil-separator reduces losses, due to the oil agitation.

 

Noise, Vibration and Harshness

 

With the installation of the new 2.2-litre D-4D, the Corolla Verso has received a new NVH package. Improved features include a thicker bonnet insulator, and additional sound-insulation components in the engine compartment. The engine undercover benefits from special absorbent material, as does the fender liner, which profits from absorbing acoustic material. The level of thickness has also been increased on both the floor and tunnel silencers.

Exterior design

 

The Toyota Corolla Verso is a compact C segment MPV (C-MPV) that has been designed for the modern era, providing a stylish, youthful and dynamic drive that is packed with clever design solutions.

 

Designed by Toyota’s European design centre, ED2, based in the south of France, the exterior incorporates powerful and dynamic exterior lines with design cues from other Toyota car. Strong exterior lines help create an athletic structure that feels robust yet at the same time hints at a dynamic drive.

 

The Toyota Corolla Verso is a challenge to the way the consumer views cars in this segment. The old notion that practicality should automatically mean pragmatic and “boxy� design has been challenged with this car. “Solid, sporty, urban and dynamic� are words which best describe the Corolla Verso. This thoroughly modern car is unmistakably a Toyota.

 

Interior design and comfort

 

The interior of the Toyota Corolla Verso represents a big step forward in car design. Although form follows function in this car, touch and sound have been tuned to the highest quality. The centre console occupies the focal position from whence the car’s interior has been designed.

 

Subtle colours and stylish metallic inserts allow for a sense of harmony and balance in the cabin space. The use of fine new fabrics that hint at a higher degree of quality, the sheer attention to detail and a flush finish all make the Toyota Corolla Verso a truly desirable vehicle to drive.

 

For a compact MPV, the Toyota Corolla Verso offers outstanding interior space and a class­leading storage area, thanks to clever packaging. The car is in fact packed with innovative design solutions allowing for seven people to sit extremely comfortably in this compact car.

 

Thanks to Toyota’s Easy Flat-7 systemTM, the new Corolla Verso is the only MPV in the world that allows for all five rear seats to be folded flat. Added to this, the folding system is the easiest to operate in this segment. It is possible to fold each rear seat down with only one simple operation. Toyota engineers and designers worked together to truly understand the Corolla Verso customer’s needs, and the result is an ingenious array of storage compartments which can house all sorts of objects.

 

The Toyota Corolla Verso has been fitted with the most advanced navigation system available in this segment. The highly accurate DVD-based system has the added benefit of traffic information in the route search1. Additionally, the system includes country guides and border displays, motorway entry/exit search. A high-quality Panasonic audio system, comprising of a built-in radio, CD, amplifier, and steering controls, allows for top-quality sounds for both driver and passengers during journeys.

 

Rear-seat passengers can opt for the Toyota In-Car Entertainment System. In this case, 5-inch LCD screens are installed in the back of the front headrests and are connected to a DVD player. The best DVD film can be enjoyed via two infrared headphones. The system can also be connected to the most common game consoles as well as play several disc formats, such as VCD, audio CDs and even MP3 files.

 

The Toyota Corolla Verso provides a stylish cabin. Clever packaging has resulted in a class­beating driving position, coupled with a comfortable steering wheel and numerous innovative ideas that combine to create a serene yet pragmatic interior space.

 

Safety

 

 

The Toyota Corolla Verso is one of the top players in its segment when it comes to safety. The car has been fitted with Minimal Intrusion Cabin System (MICS), which is the same structure used in the Toyota Avensis. The impact absorbing structure of the Corolla Verso can help reduce the impact in the event of a front or side collision. It also helps to protect driver and passengers thanks to reinforcements made to the front bumper, underfloor, dash panel, floor tunnel, rockers, front pillars and door inners that minimise cabin deformation. The Corolla Verso lives up to Toyota’s reputation for safety having won a maximum five-star rating by Euro NCAP, as well as an additional four stars for child safety.

 

The car features some segment-firsts such as the innovative Cornering Assist Monitor (CAM), which helps the driver see around blind corners. A total of seven airbags, including a segment­first knee airbag, and a two-stage visual and audio seatbelt warning system come as standard.

1 Available in Austria, Belgium, Denmark, France, Germany, Italy,

the Netherlands, Spain, Sweden, Switzerland and United Kingdom

 

Top braking performance, usually associated with upper-segment cars, comes courtesy of a system borrowed from the Toyota Avensis. Four discs bring the car to rest safely with the help of anti-lock brakes (ABS), Electronic Brakeforce Distribution (EBD) and Toyota’s own Brake Assist. Vehicle Stability Control (VSC) and Traction Control (TRC) are available throughout the range.

Range and powertrain line-up

 

 

The new Toyota Corolla Verso offers a selection of engines and grades to suit all tastes and needs.

 

Toyota has added a new Luna Pack to the Corolla Verso range. This has been positioned in the mid-range between the Terra and Sol grades. It adds to the Terra grade: manual air conditioning, front fog lamps, front & rear power windows, leather steering wheel and gear knob, front armrests and other specific design details. The Luna grade is available on all engines apart from the D-4D 180 which comes with a new Premium Active Pack.

 

The Premium Active Pack is exclusively made for the high-end diesel engine. It offers a complete package of specifications and includes sporty and premium features such as 17 alloy wheels, privacy glass and scuff plates normally associated with more premium cars. Inside, visual sophistication has been enhanced with the option of a specific, sportive premium trim, a perforated leather steering wheel and gear knob with silver stitches.


Sales update and segment share

 

Plan to increase C-MPV segment share from 4.8% to 6.4% in 2005

Over 95,000 units expected to sell in 2005

 

The new Toyota Corolla Verso has been on the road to great success since its launch in 2004 and has so far captured the enthusiasm of more than 62,000 male and female motorists. Toyota aims to sell over 95,000 units of the Corolla Verso this year and to increase its segment share from 4.6% to 6.2% this year.

 

The diesel share in this segment was 63.1% in 2004 and this figure is to increase substantially in the future. With the arrival of the new D-4D 135 and D-4D 180, the Corolla Verso will certainly respond to most of the diesel customer expectations.


The 2.2 D-4D diesel engine range

 

2.2 D-4D diesel engines: driving pleasure

 

Two new 2.2 D-4D diesel engines (177 DIN hp and 136 DIN hp) completing the Corolla Verso engine range

The second Toyota model after Avensis to be fitted with 2.2 D-4D diesel engine

 

The Corolla Verso joins the Avensis in becoming the second Toyota model to be fitted with the clean power 2.2-litre D-4D 177 DIN hp diesel engine. This, in addition to the availability of a 136 DIN hp version (D-4D 135), represents a significant step forward for Toyota in the C-MPV segment.

 

Whereas the D-4D 135 targets the heart of the C-MPV sector, the D-4D 180 puts the Corolla Verso up against the most powerful diesel cars in this segment. It features the most advanced technologies available today, including an all-aluminium cylinder block construction, highest­pressure piezoelectric common-rail system, latest-generation ceramic glow plugs and the

unique Toyota Diesel-Clean Advanced Technology (D-CAT).


Engine construction

 

 

Both the D-4D 135 and D-4D 180 diesel engines now available on the Corolla Verso have been developed using an all-aluminium body.

 

The reduction in weight ensures a substantial decrease in fuel consumption and therefore harmful emissions. The choice of materials also helps with the vehicle’s driving dynamics through more favourable front/rear weight distribution.

 

Toyota has substantial experience in replacing cast iron with aluminium for its diesel units, as was the case when it developed the acclaimed 1.4-litre D-4D installed in the Yaris, which became the world’s first diesel unit produced entirely in aluminium.

 

The high-quality, thin aluminium die-cast cylinder head-cover adopts a curved surface to achieve low combustion noise and weight reduction simultaneously. The cylinder bores use cast-iron liners for greater resistance to wear. The water and the oil pump having been built into the all-aluminium die-cast chain cover to further reduce weight.

 

As a further weight-reduction measure, the oil cooler has been produced in aluminium. Another ingenious feature in the 2.2 D-4D engine is that the water and oil pumps, traditionally separate components, have been fully integrated into the chain cover. Such a construction allows the oil pump to become 5% lighter and 20% more compact than its competitors.

 

In addition, 2mm wide piston oil rings which feature a lower tension have been adopted. This allows for a reduction in friction.

Special engine features

 

 

Toyota Computer Controlled System (TCCS) has been adopted specifically for both diesel units. It helps achieve high performance whilst at the same time delivering lower fuel consumption. TCCS controls fuel injection, injector timing, Idle Speed Control (ISC), fuel pressure, glow relay, EGR and air conditioning cut.

 

A new intercooler has been installed on the D-4D 135 and D-4D 180 diesel engines. It features a heat exchange area eight times bigger than its predecessor. As a result, heat exchange efficiency has risen from 68% to 90%. This plays a crucial role in improving the volumetric efficiency and, consequently, performance.

 

To reduce engine noise, an offset piston with skirt’s shape and optimised rigidity as well as scissor gear-driven two-axle balance shafts have been adopted.

 

Friction has been dramatically reduced and fuel economy enhanced by simply adopting a roller rocker arm built into the needle bearings.

 

The need for maintenance has been kept to a minimum by installing a compact hydraulic lash-adjuster. This helps reduce the size of the valve-operating system, as well as achieve high valve lift.

 

An oil filter with a replaceable element has been introduced to the 2.2 D-4D and the number of non-combustible replacement parts has been reduced.


Manufacturing

 

 

The new D-4D engine family is produced at Toyota’s latest European plant in Jelcz-Laskowice, Poland. Toyota Motor Industries Poland (TMIP) is the carmaker’s eighth production plant in Europe. The plant is a showcase for Toyota’s on-going commitment to provide its European customers with the best diesel engines on the market.

 

Toyota has invested in the region of €200 million in the TMIP plant and many jobs have been created in this once deprived region. Averaging 27 years old, the TMIP workforce are as young and dynamic as the engines and technology they are producing.

 

October 2002 marked the official announcement of the decision to invest in TMIP. The construction of the plant, which began in April 2004, was completed in a record 8 months –extremely fast for a manufacturing base of its size and calibre. Employee training and production trials began, meanwhile, between August 2004 and March 2005.

 

Production of the new 2.2 D-4D engines started on the 21 st March 2005 for Avensis. Now TMIP is operating the machinery of two main components besides full engine assembly.

 

Operations are expected to expand at the beginning of 2006, with more machine-work being carried out in-house. The casting of the three main parts is also expected to take place at TMIP next year.

 

Toyota expects to reach full production capacity, which it sees as 180,000 units, as early as 2007, when a second production shift is added.

 

As for as vehicle manufacturing, the Toyota Corolla Verso is the third model after Corolla sedan and wagon to be produced at Toyota Motor Manufacturing Turkey (TMMT), TMMT is one of Toyota’s main manufacturing sites in Europe. Established in 1990, it represents a total investment of €700 million by Toyota and has a total production capacity of 150,000 units.

D-4D 180 Clean Power

 

Corolla Verso flagship engine

 

The D-4D 180 is the first truly high-power diesel in the C-MPV segment. The engine delivers an impressive 400 Nm of torque at an ultra low 2,000 rpm, giving the Corolla Verso a sporty yet smooth feel. As well as being practical and safe, this compact C Segment car sprints from 0-100 km/h in just 9.0 seconds, before reaching a top speed of 205 km/h. Surprisingly, fuel

consumption has been kept to an absolute minimum.

 

“Clean Power� really does live up to its name, and the 177 DIN hp 2.2 with Toyota D-CAT technology in the Corolla Verso maintains the lowest emission rates in its segment, thanks to the Diesel Particulate NOx Reduction system (DPNR).


Sophisticated injection and induction technologies

 

 

The majority of current common-rail systems employ solenoid injectors, which are actuated by a magnetic field generated by an electric current. The D-4D 180 diesel engine in the Toyota Corolla Verso, on the other hand, uses piezoelectric technology. This is the first time in this segment that such technology has been used.


Piezoelectric injector


The principle behind this is the capacity of certain materials to deform upon the application of an electrical charge and to return to their original state when the current is removed. The same concept is used on this engine, where each injector is composed of a stack of piezoelectric ceramic elements. When an electric current is applied to the stack, the elements expand instantly, allowing the fuel from the common-rail to be injected into the cylinder. Thus, larger volumes of fuel can be injected in a shorter time than was possible with conventional injectors. This in turn leads to greater fuel atomisation and more precise injection timing.


Injection rate


The new injection system has many advantages. For instance, Toyota’s new piezoelectric injectors are 2 times quicker than solenoids when producing an injection and can perform up to 5 injections per cycle with single pilot injection at hot idle, and multiple injection at partial load. With piezoelectric technology, pilot injection timing can be optimised, leading to a handsome reduction in combustion noise.

Toyota’s piezoelectric common-rail system produces the highest injection pressure (1,800 bar) and the highest number of injections per cycle (5 in total) among systems of this type.


Low compression ratio

 

At 15.8:1, the D-4D 180 boasts the segment’s lowest compression ratio which means that the engine needs less effort to compress the mixture. This results in higher efficiency, better performance, lower fuel consumption and one of the lowest Noise, Vibration and Harshness (NVH) in its sector.

Leaner diesel engines adopt a high air/fuel mixture, which tends to produce higher levels of nitrous oxides (NOx). This is mainly because they cannot use a larger amount of fuel to reduce the heat build-up in the piston bowl. This, in turn, leads to higher combustion temperature. However, by reducing the compression ratio it is possible to decrease the combustion temperature with a positive impact on the generation of NOx. This is what Toyota engineers have achieved with this diesel engine.

 

Furthermore, by reducing the compression build-up inside the cylinder and combustion chamber, it is also possible to reduce the noise and vibration caused by each explosion. This clever solution allowed Toyota engineers the freedom to develop lighter moving parts as well as a lightweight aluminium block. Surprisingly, the weight reduction has had no negative effects on the durability and reliability of the unit.

 

The low compression ratio has only been made possible by adopting a state-of-the-art diesel technology in components such as the new-generation common-rail system and glow plugs.

Ceramic glow plugs

 

The D-4D 180 has been equipped with ceramic glow plugs, a technology pioneered by Toyota.

Ceramic glow-plug

 

Few materials have greater heat-resistance than ceramics. Its ability to withstand much higher temperatures allows the Toyota ceramic glow plug to maintain the same efficiency rates for a much longer period than conventional metallic glow plugs would allow. This is an obvious advantage when it comes to durability.

 

Furthermore, the thermal conductivity of ceramics far exceeds that of metals. Therefore, the ceramic glow plugs are able to reach the ideal temperature quicker than metallic ones. This leads to more rapid cold starts at lower air temperature.

 

Toyota engineers have equipped the D-4D 180 with an evolutionary ceramic glow plug, which is now able to reach a much higher temperature, 100 °C higher than the previous generation.

 

The new generation of ceramic glow plugs also reduces the formation of white smoke thanks to the fact that the combustion chamber reaches more rapidly the ideal temperature.

Toyota D-CAT technology

 

Toyota D-CAT resulted in 1,622 new patents for Toyota

 

The Toyota Diesel Clean Advanced Technology (D-CAT) is an integrated suite of technologies that have been combined to reduce harmful emissions to the lowest level seen in any modern diesel engine today. The technology allows the engine to surpass strict EURO IV emission standards by greatly reducing hydrocarbons (HC), Carbon Monoxide (CO), Nitrogen Oxides (NOx) and Particular Matter (PM) emissions.

 

Thanks to Toyota’s D-CAT, the D-4D 180 Clean Power engine boasts the smallest combined NOx and PM emissions in comparison to all diesel engines of its segment.


The catalyst features a highly absorbent ceramic filter. Its density is 300 cells per square inch and it is mounted close to the exhaust manifold. A simple oxidation catalytic converter has been placed further downstream in the exhaust system.

 

In the DPNR purification process, during conventional lean-burn combustion, particular matter is first oxidised using active oxygen which has been created when NOx is temporarily stored in the catalyst.

 

Then, through a “rich spike� that has been generated through the Exhaust Port Injection (EPI, explained below) the engine switches momentarily to rich condition and the stored NOx is reduced, producing more active oxygen. This in turn is used to further oxidise particular matter inside the catalyst.

 

Most crucially, and unlike most particular filters found on the market, DPNR is maintenance­free and doesn’t require any component replacement.

 

Exhaust Port Injection (EPI)

 

The DPNR catalyst can operate effectively because the engine management system is able to vary the air/fuel ratio in the exhaust gasses. Therefore, a fifth injection nozzle has been added and placed in the exhaust port to serve this purpose. This is called Exhaust Port Injection (EPI).

 

At the critical moment, fuel is injected into the exhaust manifold at a pressure of 7 to 10 bar so as to create a stoichiometric condition in the DPNR catalyst. This “rich spike� allows the DPNR catalyst to reduce the stored NOx.

 

The Exhaust Port Injection (EPI) is also used to perform the sulphur discharge control. When a certain sulphur level has been reached, the EPI helps increase the catalyst’s bed temperature to a level in which excess sulphur begins its discharge process.

Exhaust Gas Recirculation (EGR)

 

Toyota’s D-CAT uses a high-response Exhaust Gas Recirculation (EGR) valve in order to helps reduce the amount of smoke generated during acceleration. The linear solenoid-type valve boasts twice the discharge rate of the old 2.0 D-4D engine. This results in a much higher flow of exhaust gas recirculation. The new EGR valve also has a quick response mechanism, which means it takes much less to switch from closed to completely open.

 

The large capacity and highly efficient EGR cooler reduces the temperature of the exhaust gasses that are recirculated into the combustion chamber. The cooler the exhaust gasses, the greater their density, therefore allowing a larger mass of EGR gasses to be fed into the combustion chamber each time.

 

The engine incorporates a by-pass valve in the EGR circuit. This allows it to divert the re­circulated gasses through a different path which avoids the cooler. Therefore EGR can operate even in the coldest of conditions, reducing emissions.

 

The Toyota D-CAT’s flawless operation relies on a constant stream of accurate data being supplied to the engine management system. The data, crucial to the effectiveness of Toyota D-CAT, is provided by a range of 15 sensors that monitor several different parameters. For example, there is an air/fuel ratio sensor, situated after the DPNR catalyst exit, a gas temperature sensor, housed before the entry and after the DPNR exit and a differential pressure sensor, which monitors the pressure differential between the intake and exhaust of the DPNR catalyst.

 

Driving Pleasure

 

The D-4D 135 diesel engine variant enables the Corolla Verso to exhibit its excellent performance potential. Combined with Toyota’s 6-speed transmission system, it proves to be a more dynamic drive than others in this segment.

 

The D-4D 135 Corolla Verso is nippy, accelerating to 100 km/h in a mere 10.0 seconds. At 2000 revs, 310 Nm of torque kicks in, ensuring the Corolla Verso offers the driver smooth overtaking capacity. Just to compare, on the 116 DIN hp 2.0 D-4D, maximum torque stood at 280 Nm. It returns a combined fuel consumption of 6.3L/100km

 

An evolution in more than one way

 

 

Even though the outgoing engine was very competitive with other diesel engines on the market, Toyota saw the need to evolve it even further, making various modifications to better suit the structure and driving needs of Corolla Verso customers.

 

For the first time in this segment, the D-4D 135 has been equipped with an aluminium cylinder block, which helps achieve significant weight loss on the engine. It makes the engine 13% lighter than the 2.0 D-4D engines.

 

The D-4D 135 adopts a rotary solenoid diesel throttle so that fresh air is regulated more rapidly. This in turn reduces diesel smoke, combustion noise and combustion instability.

 

One of the key factors in the great efficiency and low NVH of the D-4D 135 diesel engine is its very low compression ratio, 16.8:1. This means that the engine needs less effort to compress the mixture and allows more power output teamed with less fuel expenditure and, of course, lower NVH levels.

 

It now has improved fuel atomisation and, therefore, a more homogeneous mixture, resulting in a more efficient combustion process. This is mainly thanks to the engines 1,700 bar, which represents a 6% improvement on the 2.0 D-4D engine.

 

The D-4D 135 engine on the Corolla Verso uses improved metallic glow plugs. They can now achieve 12% higher temperatures than the glow plugs installed in the previous 116 DIN hp 2.0 D-4D, providing a more rapid cold start, which is particularly noticeable at extremely low temperatures.

New 6-speed manual transmission

 

Both derivatives of the 2.2-litre D-4D diesel engines in the Corolla Verso range come with Toyota’s 6-speed manual transmission system which boasts class-leading levels of smooth, quick and precise gear-change.

 

A multi-cone synchroniser from first to fourth gears, which requires less force to manoeuvre, has contributed to the sense of smooth and more precise gear-shifting. The gearbox uses a slide ball-bearing in the select lever shaft and fork shaft (for high shift efficiency) as well as a shift-guide plate to decrease the amount of free play after shift. The re-shaped mass damper also improves shift smoothness.

 

Both engines share the same gear ratios; except for 6th gear, where the 177 DIN hp version benefits from a longer ratio in comparison with the 136 DIN hp engine.

 

Another clear advantage of the 6-speed manual transmission gearbox is that it is robust in construction. With its exceptionally compact structure, a mere 384 mm in length, it beats all other 6-speed transmissions of identical or even inferior torque capacity. The use of a 3-axis construction has allowed for a 17% reduction in length, compared to the normal 2-axis configuration.

 

Fuel consumption has been reduced by 1%, thanks to the lowest viscosity oil available today for manual transmissions. Adoption of an oil-separator reduces losses, due to the oil agitation.

 

An aluminium oil separator inside the gearbox reduces turbulence losses by preventing the oil in the sump from being directly stirred by the output shaft, which generates undesired oil agitation. Furthermore, the shaft bearings have lower friction co-efficiency than the ones adopted for the 5-speed manual gearbox driving the outgoing 2.0 D-4D engine range.

 

Toyota engineers have technically developed the clutch system in order to meet the high level of overall refinement expected from the 2.2 D-4D engine unit. The adoption of a self­adjustment system allows for a reduction on the clutch cover load. This reduces face wear and at the same time results in less initial effort to depress the clutch pedal.

 

Transmission rattling and low-speed booming noise have been substantially reduced thanks to major improvement in the clutch unit. A dual-mass flywheel, composed of two main parts (input side and output side), is articulated through four arc-type springs, which in turn provide efficient damping against the engine’s acceleration and torque fluctuation.

 

Last but not least, the transmission offers a wider gear-range which help reducing fuel consumption. This has been made possible using a 6-speed configuration that adopts different lengths between the input shaft and each of the output shafts. The final gear ratio exceeds 7:1.





















Technical specifications

 

Engine

D-4D 135

 

D-4D 180

Type

L4 w/ Variable Nozzle Turbocharger and intercooler

Cylinder head material

Aluminium

Engine block material

Aluminium

Fuel type

48 cetane diesel (or more)

Injection type

Direct injection common-rail, multiple fuel injection

Emission control system

Oxidation catalyst

Toyota D-CAT + oxidation

catalyst

Valve mechanism

DOHC 16-valve

Displacement (cm3)

 

2,231

 

Bore x stroke (mm)

 

86.0 x 96.0

 

Compression ratio (:1)

16.8

 

15.8

Injection pressure (bar)

1,700

 

1,800

Max. power (kW) DIN hp/rpm

(100) 136@3,600

 

(130) 177@3,600

Max. torque (Nm/rpm)

310@2,000-2,800

 

400@2,000-2,600

 

Transmission

Drive type: Front wheel drive

Gearbox: 6-speed

Type: manual

 

Gear ratios

1st

3.538

 

3.538

 

2nd

1.913

 

1.913

 

3rd

1.219

 

1.219

 

4th

0.881

 

0.881

 

5th

0.810

 

0.810

 

6th

0.674

 

0.638

 

Reverse

3.831

 

3.831

Final gear ratio   1 st - 4th

4.059

4.059

 

5th, 6th, Reverse

3.450

3.450

 

Performance

Max. speed (km/h)

195

205

0-100km/h (s)

10.0

9.0




* According to Directive 1999/100/EC Other emissions* (g/km)

 

47
The details of specifications and equipment provided in this press information are subject to local conditions and requirements and may, therefore, vary from country to country. Toyota Motor Marketing Europe reserves the right to alter any details of equipment and specifications without prior notice.