ENGINE

3GR-FSE FUEL

EG75

3GR-FSE FUEL
General
This engine uses the D-4 (Direct injection 4-stroke gasoline engine) system. A (low pressure) fuel pump located inside the fuel tank pumps
fuel to the high-pressure fuel pump located in the cylinder head cover. Then, the fuel is boosted to a pressure between 4 and 13 MPa in
accordance with the driving conditions, and sent to the high-pressure fuel injectors.
To enhance cold starting performance, a (low pressure) cold start fuel injector is provided in the surge tank.
A fuel returnless system, which controls the fuel pressure for the low pressure side by way of a pressure regulator installed in the fuel tank,
is used. However, the leak fuel from the high-pressure fuel pump and the fuel from the relief valve return to the fuel tank.
To prevent fuel from leaking during a collision (in which air bags are deployed), a system that turns OFF the circuit opening relay is used
to ensure safety.

Fuel Pump (High Pressure)

Cold Start Fuel Injector *
Charcoal Canister

Delivery Pipe(Right)

Fuel Pump(Low Pressure)

High-Pressure
Fuel injector
Delivery Pipe(Left)
*:Only U.S.A. and Canada

Fuel Tank
A4270036P

Direct injection 4-stroke Gasoline Engine (D-4)

The D-4 (Direct injection 4-stroke gasoline engine) directly injects highly pressurized fuel into the cylinders. This engine effects comprehensive control of the fuel injection timing, air-fuel ratio, throttle valve position, etc., to realize both a high power output and low exhaust

EG76

ENGINE
3GR-FSE FUEL

emissions.
The high-pressure slit nozzle injector atomizes fuel into a fine mist while expanding it to form a large, fan-shaped pattern. Then, the fuel
mist enters the combustion chamber while drawing in a large volume of air. The fuel mist that is sprayed at high pressure expands into the
combustion chamber on its own energy, without depending on the air current. Thus, it mixes efficiently with the intake air in order to
achieve ideal combustion in all driving ranges.

Injector

Direct injection 4-stroke Gasoline Engine(D-4)

A4270037P

Air Fuel Ratio Control

One of the two independent straight ports contains an SCV (Swirl Control Valve), which opens and closes to enhance both charging efficiency and combustion efficiency.
When the engine is operating at low speed and low load conditions, the SCV remains fully closed. Thus, only one port is used for intake,
in order to promote the mixture of air and fuel. This also accelerates the intake flow speed, which enhances combustion and improves
fuel economy.
When the engine is operating at high load conditions, the SCV opens to allow the intake of air through both straight ports. This increases
the intake air volume and improves charging efficiency. At the same time, this creates a vertical swirl current (tumble current) in the
combustion chamber to promote the mixture of air and fuel, thus improving performance.
Fuel is injected during the compression stroke immediately after cold-starting. This enables the catalyst to warm up quickly, resulting in
a dramatic reduction in exhaust emissions.

ENGINE
3GR-FSE FUEL

Intake Stroke

Injection During Compression Stroke

EG77

Ignition

Conceptual image of fuel injection during cold starting

A4270038P

Fuel Pump
A fuel pump assembly consisting of a (low pressure) fuel pump, fuel filter, and sender gauge is used.
To prevent fuel from leaking during a collision (in which air bags are deployed), a system that turns OFF the circuit opening relay, in accordance with a signal from the airbag ECU, is used to ensure safety.

EG78

ENGINE
3GR-FSE FUEL

Fuel Pump
Fuel Filter

Pressure Regulator
Sender Gauge

A4270033P

Fuel Pump
Discharge Pressure [kPa]

400

Discharge Volume [Lh]

190 Minimum

Fuel Filter
Filter System
Filtering Surface Area [cm2]

Paper Filter Type

1550

Fuel Pump Control

When the starter signal is ON and the engine speed signal is input continuously for 2 seconds or longer, the circuit opening relay turns
ON to actuate the fuel pump.
A fuel cut control is adopted to stop the fuel pump when the airbag is deployed at the front or side collision. In this system, the airbag
deployment signal from the airbag sensor assembly is detected by the ECM, which turns OFF the circuit opening relay.
After the fuel cut control has been activated, turning the ignition switch from OFF to ON cancels the fuel cut control, thus engine can be
restarted.

ENGINE

EG79

3GR-FSE FUEL

IG Switch
IGSW

Main Relay

Front
Air Bag
Sensor
LH

MREL
+B

Circuit
Opening
Relay

+SL
-SL

+SR
-SR

Front
Air Bag
Sensor
RH

FC
Side
Air Bag
Sensor
LH

ECM
Fuel Pump Relay

VUPL
SSL+
FSL
SSR-

VUPR
SSR+
FSR
SSR-

Side
Air Bag
Sensor
RH

Air bag ECU

FPR

Gateway
ECU

Fuel Pump

CAN
BEAN
A4270034P

Jet Pump
The jet pump operates as described below.
A jet pump is adopted in the fuel tank. Since the propeller shaft is located below its center bottom, the fuel tank of the GS430 is shaped as
indicated below.
A fuel tank with such a shape tends to cause the fuel to be dispersed into both chamber A and chamber B when the fuel level is low, stopping
the fuel in chamber B from being pumped out. To prevent this from occurring, a jet pump has been provided to transfer the fuel from chamber B to chamber A.
This is accomplished by utilizing the flow of the fuel, so that the vacuum created by the fuel, as it passes through the venturi is used to suck
the fuel out of chamber B and send it to chamber A.

Pressure Regulator
Engine

Return Fuel
(From Pressure Regulator)
Venturi

Fuel Filter

Fuel Pump
Chamber B

Jet Pump

Chamber A

From Chamber B
Chamber B

Chamber A
A4270039P

Fuel Sender Gauge

To accurately inform the driver of the residual fuel volume in the saddle-shaped tank, inline sender gauges are provided in the two chambers,
A and B. These sender gauges output the residual fuel volume of both chambers to the meter ECU.
Based on the signals received from the two sender gauges and the SFI control information received from the ECM, the meter ECU calculates
the residual fuel volume, and activates the fuel gauge.

EG80

ENGINE
3GR-FSE FUEL

Meter ECU
F

Injection Volume
Information

Gateway
ECU

ECM

Fuel Gauge

Low Fuel Level

Warning Light

CAN
BEAN
Chamber A

Chamber B
Fuel Tank

A4270040P

Fuel Pump (High Pressure)

This fuel pump is a highly efficient, single-plunger type in which the drive torque has been reduced. In addition, a solenoid spill valve and
a check valve have been integrated to achieve a lightweight and compact system. Also, a pulsation damper has been installed at the lowpressure fuel inlet.
Mounted on the cylinder head cover, this fuel pump is driven by a cam that is provided at the rear end of the exhaust camshaft on the right
bank of the engine. A heat insulator is provided on the surface of the fuel pump that mounts to the cylinder head cover in order to suppress
the increase in fuel temperature.
The ECM variably controls the fuel to a high pressure that suits the driving conditions. Because this system uses a solenoid spill valve to
control and discharge only the necessary volume of fuel, the drive torque and noise have been reduced.
A fuel pressure sensor, which is provided in the fuel delivery pipe, gives feedback to the ECM in order to maintain an optimal fuel pressure
at all times. This system varies the high fuel pressure between 4 and 13 MPa to suit the driving conditions, in order to reduce friction loss.
A tapered seal metal joint is used for joining the high-pressure fuel delivery pipes.
It consists of a solenoid spill valve that regulates the discharge volume of high-pressure fuel, a plunger that is driven by the camshaft and
pressurizes fuel, and a check valve that mechanically opens and closes the passage to the fuel delivery pipe.
A pulsation damper is provided at the low-pressure fuel inlet from the fuel tank, in order to reduce the pulsation of fuel.

ENGINE

EG81

3GR-FSE FUEL

Solenoid Spill Valve

Delivery Pipe(LH)

Delivery Pipe(RH)

High-Prussure Fuel
(To Fuel Delivery Pipe)

Low Pressure Fuel

(From Fuel Tank)

Pulsation Damper

Return Fuel
(To Fuel tank)

Fuel Pump
(High Pressure)

High-Pressure
Fuel Injector

Pulsation Damper
Pressure Regulator(400kPa)

Fuel Filter

Fuel Tank

High-Pressure
Fuel Injector

Fuel
Pressure
Sensor

Solenoid
Spill Valve

ECM

Relief Valve
(15.3MPa)

Check Valve(60kPa)
Fuel Pump
(High Pressure)

Jet Pump

Feed Pump

Camshaft
A4270041P

High Pressure Fuel Pump Operation

The plunger in the pump moves up and down to pressurize fuel. The solenoid spill valve, which is provided at the suction side of the
pump, closes at an optimal timing during the compression stroke in order to control the fuel to the required pressure and volume. If the
solenoid spill valve closes at an early timing, the effective stroke of the plunger becomes longer, thus pressurizing the fuel to an even
higher pressure.
The fuel that has been pressurized by the plunger pushes open the check valve (60 kPa), flows into the fuel delivery pipe, and is controlled
to a pressure between 4 and 13 MPa (approximately 40 to 130 bars).
The fuel pressure sensor that is provided on the fuel delivery pipe detects the fuel pressure and gives feedback to the engine ECU, enabling the engine ECU to control the fuel to a target pressure.

EG82

ENGINE
3GR-FSE FUEL

Plunger Lift

Solenoid Spill Valve Open

Solenoid Spill Valve Close
Valve Opening
Pressure Control

Solenoid Spill Valve

Return

Plunger

Check Valve

Suction

To Delivery Pipe

Freewheeling

Pumping

A4270236P

Delivery Pipe
An aluminum alloy fuel delivery pipe is used.
A fuel pressure sensor and a relief valve are provided on the fuel delivery pipe.
An injector clamp is provided to each area of the fuel delivery pipe where a high-pressure fuel injector is installed. This clamp applies a
constant spring force to the injector to prevent the injector from moving when the combustion pressure is applied to the injector while the
engine is being started, during which the fuel pressure is low. As a result, it increases the sealing performance of the injector, while reducing
vibration and noise.
O-rings and backup rings* are used in the areas in which the high-pressure fuel injectors and high-pressure fuel delivery pipes are joined.
This reduces the transmission of the operating sounds of the high-pressure fuel injectors, enhances quiet operation, and ensures the sealing
performance of the joined areas.
REFERENCE
*:The backup ring is provided to securely support the rubber O-ring, which is exposed to high fuel pressure. During assembly, make sure to install it with the correct
position and orientation.

ENGINE
3GR-FSE FUEL

EG83

Backup rings
Backup rings

O-ring
O-ring
O-ring
Backup rings3

Fuel Pipe

Backup rings3
O-ring
Delivery Pipe(RH)
Fuel Pressure Sensor

Backup rings3

Gasket

O-ring
Injector
Clamp
High-Pressure
Fuel Injector

Gasket
Relief Valve

Delivery Pipe(LH)
A4270043P

Relief Valve
A relief valve is provided in the fuel delivery pipe. When the fuel in the fuel delivery pipe increases to a predetermined pressure (15.3
MPa), the relief valve returns the fuel to the fuel tank.

Fuel Delivery Pipe

Fuel exit

Sectional view

A4270044P

Injector
A single-orifice, high-pressure slit nozzle injector is used.
The injector atomizes fuel into a fine mist and expands it to form a large, fan-shaped pattern. Then, the fuel mist enters the combustion
chamber while drawing in a large volume of air. This increases the intake air volume and improves charging efficiency. Furthermore, the
intake air forms a vertical swirl current (tumble current) in the combustion chamber to promote the mixture of air and fuel, thus achieving
high performance and a high power output.
Because the injector is exposed inside the combustion chamber, a special coating has been applied to the nozzle in order to suppress the
adhesion of carbon deposits created by the combustion gas.
An insulator is used in the area in which the injector comes in contact with the cylinder head, and a Teflon shaft seal is used for sealing the
injector against the cylinder pressure in order to reduce vibration and noise and enhance sealing performance.
An EDU (Electronic Driver Unit) is used in order to operate the high-pressure fuel injectors speedily and precisely.

EG84

ENGINE
3GR-FSE FUEL

Insulator

Nozzle
Teflon Shaft Seal

High-Pressure Fuel Injector Cross-Sectional Diagram

A4270032P

Fuel Injector
Number of Orifices

Orifice Dimensions [mm]

0.150.71

Injection Pressure [MPa]

4 ~ 13

Cold Start Fuel Injector

A cold-start fuel injector is used for improving cold-starting performance. It is provided in the surge tank of the intake manifold and injects
fuel when the engine is started at low engine coolant temperature.
Cold Start FuelInjector
Number of Orifices
Flow Rate

[cm3/min.](at3001.5kPa)

2
12012.0

Operating Conditions
Engine Coolant Temperature

At the time of low water temperature

ENGINE
3GR-FSE FUEL

EG85

Surge Tank

Cold Start Fuel Injector

Cross-Sectional Diagram

Cold Start Fuel Injector

A4270277P

EDU(Electronic Driver Unit)

An EDU to operate the high-pressure fuel injectors at high speeds is placed in the engine compartment. The EDU converts the injection
request signal received from the ECU into high-voltage, high-amperage injector actuation signals, in order to actuate the high-pressure fuel
injectors.

EDU Operation
EDU Operation (Circuit Diagram 1)
When the ECM sends injection signals (IJt-1 to IJt-6) to the EDU, the COM terminal outputs a high voltage for actuating the injectors.
When the injectors open the voltage switches to 12V to keep the injectors open. The current will flow from INj#+ to INj#- and to GND,
in order to actuate the high-pressure fuel injectors.
The control circuit constantly monitors the actuating state of the injectors, and sends an IJf fail signal to the ECM when the INj-# is actuated normally.

EG86

ENGINE
3GR-FSE FUEL

EDU

(Circuit Dgram 1)

FP+
INj6+
INj3+
INj5+

+B

INj2+
INj4+
High Voltage
Generating
Circuit

INj1+

IJt-1
INj1IJt-4
INj4IJt-2
INj2IJt-5

ECM

INj5-

Control Circuit

IJt-3

INj3-

IJt-6

INj6-

IJf

High-Pressure
Fuel Injector

FPD
Solenoid
Spill Valve

FP-

FPF

GND

A4270045P

Example of IJt-1 Actuation (Circuit Diagram 2)

The fuel injection request signal IJt-1 from the ECM passes through the waveform shaping circuit, and separates into the monostable
circuit - high side switch and the driver circuit. Then, the high side switch applies the high voltage boosted by the DC-DC converter, in
accordance with the fuel injection request signal, from the INj1+ and INj4+ terminal to the INj1- and INj4- terminals (injectors #1 and
#4).
In accordance with a signal received from the waveform shaping circuit, the driver circuit grounds the INj1- terminal in a timely manner,
in order to control the fuel injection volume and injection timing of injector #1.

Circuit Diagram 2

Noise Filter

DC-DC Converter High Side Switch

+B
INj4+
INj1+
GND
Charging Control

ECM

IJt-1
IJt-4
IJf

Waveform
Shaping

Monostable
Fail Detection

Driver

INj1INj4-

Stable Current
A4270046P

Fuel Tank
The fuel tank is mounted in the center of the vehicle, forward of the rear axle. It has a capacity of 71.0 liters.

ENGINE
3GR-FSE FUEL

EG87

The fuel tank adopts a saddle shape to allow the propeller shaft to pass through its center portion.
Two sender gauges (main, sub), fuel pump, fuel filter, pressure regulator, and jet pump have been integrated.
Fuel draining marks have been provided on the bottom of the fuel tank. These marks clearly indicate the position for aligning the fuel draining device during dismantling, and simplify and ensure the reliable draining of fuel.

Fuel Draining
Marks

Fuel Tank Bottom View

A4270047P

Plastic Fuel Tank

A fuel tank made of plastic is used for weight reduction. It consists of six layers of plastic to ensure the long life of the tank and the low
permeation of fuel.

HDPE
Tank Exterior

In-Process Recycled Material

Adhesion Layer
Barrier Layer
Adhesion Layer

Tank Interior

HDPE
*HDPE(High Density Polyethylene):High Density Polyethylene It is lightweight,
high strength,and excels in water and solvent resistance.

Layer Composition of Fuel Tank

A4270048P

EG88

ENGINE
3GR-FSE FUEL

Charcoal Canister
Canister purge control is used to draw the fuel evaporative gas created in the fuel tank into the intake port, to be burned during combustion.
The charcoal canister is mounted behind the fuel tank.
An internal pressure control valve is provided at the fuel passage inlet from the fuel tank in order to maintain the proper pressure in the fuel
tank.

Charcoal Canister

Pump Module
From Fresh Air Line

To Intake Manifold

Refueling Valve

From Fuek Tank

A4270049P