Special Feature

2Offering New Clean Diesel Engines with
Significantly Enhanced Environmental
Performance to Customers around
the World
Sustainable growth of the global automobile market is expected to continue primarily in emerging countries.
At the same time, environmental regulations are increasingly becoming more stringent in both developed andemerging countries. In response, there is a growing demand for diesel engines that feature superior fuelefficiency and emit less CO2. Amid such conditions, Toyota Industries’ Engine Division has worked closelywith Toyota Motor Corporation (TMC) in the diesel engine business in various areas, including development,production engineering and production.
In this special feature, we introduce the initiatives undertaken for the development and production of a
new diesel engine, which simultaneously realizes superior power performance and environmental
performance, as well as a turbocharger (hereafter, turbo) that plays a significant role in the enhancement ofthese performances.

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Toyota Industries Report 201531

Special FeatureParticipating in the Launch of TMC’s New
Environment-Conscious Diesel Engines fromthe Development Stage
Leveraging long-accumulated diesel engine technologies,
we participated in the development of the GD diesel engines(1GD-FTV and 2GD-FTV), successor models of TMC’s
mainstay KD engine. In June 2015, our Higashichita Plant inAichi Prefecture commenced production of the 1GD-FTV, a2.8L direct-injection turbo diesel engine fitted on the Land
Cruiser Prado and the Hilux that are marketed in Japan andThailand, respectively.
The GD diesel engine, together with the 2GD-FTV 2.4L
direct-injection turbo diesel engine, is fitted on approximately
70% of TMC’s diesel-powered vehicles, and was developed
in response to needs for cleaner engines both in developed
countries where more stringent emissions standards arebeing enforced and in emerging countries where emissions
standards are expected to be strengthened. The newly
developed GD diesel engine adopted next-generation
advanced thermal insulation diesel combustion that uses
Thermo Swing Wall Insulation Technology (TSWIN)*1 for the
first time in the world as well as the turbo for which weparticipated in the development. Together, these twofeatures enable maximum thermal efficiency of 44%, one of
the highest in the world. Compared with the KD dieselengine, the GD model offers significantly enhanced
environmental performance, such as an approximately 15%
reduction in CO2 emissions at maximum. In terms of power
performance, the starting torque and acceleration response
have been dramatically improved. Further, the adoption of
the urea Selective Catalytic Reduction (SCR)*2 system, a
TMC first, and other features clear Euro 6, the world’s moststringent emissions standard, as well as Japan’s 2010
emissions standards and other regulations.
*1: Combustion improvement technology to reduce cooling losses during combustion*2: Technology to neutralize nitrogen oxides in emission gases using urea

Toyota Industries’ Engine Business
Possessing a History of Innovation andChallenges
Toyota Industries entered the Engine Business in 1953.
Production expanded from automotive gasoline engines toautomotive diesel engines and subsequently to engines forindustrial use, including lift trucks, by applying thetechnologies for automotive engines. We have thus steadilybroadened our scope of the Engine Business.
At present, we produce such automotive engines as KDdiesel engines, which are fitted in TMC’s Innovative
International Multi-purpose Vehicle (IMV) series; VD diesel
engines adopted in the Land Cruiser and other vehicles; andAR gasoline engines installed in the RAV4 and othervehicles. For industrial use, we also produce Toyota 1KD
diesel engines, Y gas/gasoline engines and other engines
and fit them in our lift trucks and other industrial vehicles.
Among these, we play a particularly major role in thedevelopment and production of TMC’s diesel engines,
contributing to their production of appealing diesel-powered
vehicles by tapping our strengths in terms of development
and production aspects such as the development of clean,fuel-efficient and high-performance engines as well as highmix low-volume production through flexible production lines.

New Engine Meeting the Globally Rising
Expectations for Clean Diesel Engines
While automobiles are becoming increasingly electrified, as
exemplified by hybrid vehicles and electric vehicles, inEurope diesel-powered vehicles have long been highly
appreciated for their effectiveness in countering global
warming because they are fuel efficient and produce less
CO2 emissions compared with gasoline-powered vehicles.
Also, in terms of power performance, diesel engines could

Applying Our Strengths Such as Technologies
and Know-How Cultivated in the Compressor
Business to the Development of the Turbo,a Key Component
More often than not, an engine’s power performance andenvironmental performance are determined by thecapabilities of the turbo installed inside the engine. For thisComments from Engine Developers(Engineering Dept., Engine Div.)TakeyukiKato(Thousand units)
800■ Gasoline■ Diesel
700
600
500
400
300
200
100

66

7176

81

8691

960106

11

Toyota Industries Report 2015

Working leader

Comparison of GD Engine and KD Engine■ Maximum torque■ Low speed torque■ CO2 emissions

(N·m)

(N·m)

(g/km)

500

400

300

400
Good

300

Good300

Good

200

200
200

100
100

1000KD
GD(2.5L) (2.4L)

00KD
GD(2.5L) (2.4L)

KDGD(2.5L) (2.4L)

reason, improvements in turbos are indispensable asemissions standards become ever more stringent
worldwide. Naturally, our endeavor to develop the world’s
best diesel engines entailed the development of the world’s
best turbo.
However, four leading turbo manufacturers alreadyaccount for more than 80% of the global market, and it wasconsidered that there was no room for new entrants.
Undaunted by this disadvantage, we participated in TMC’s
project to develop diesel engine turbos for automobiles andsuccessfully commenced production in February 2015.
For the launch of the turbo, we drew upon the strengthsof each of our diverse businesses, including close
cooperation with the GD diesel engine development team,know-how cultivated in the Car Air-Conditioning
Compressor Business as well as the experience in 2013 toinstall a new internal-combustion lift truck with our firstindustrial turbo developed and produced in-house.
In the turbo development, a particular focus was placedon realizing lighter weight and a more compact size whileachieving high efficiency at the same time. In order toefficiently reroute exhaust energy back into the engine, wereviewed the basic framework and materials, changed
production methods and incorporated various ingenuities. In
addition, since the pleasure of driving is an essential element

15*Including lift truck engines and excluding CKD

32Taku Ishikawa

We set a technically challenging goal for thedevelopment of the GD diesel engine in order tosignificantly improve performance, with all relevant
departments such as development, quality assurance
and production engineering working together as one
team.
For example, we aimed to reduce the number ofbolts to tighten one cylinder from six to four in order torealize the optimum design of the port, but that entailed
the problem of inadequate sealing of the cylinder head.
Also, improving engine performance gave rise to such
issues as thermal load and stress on the cylinder head,requiring a review of the structure and materials as well.
With the difficultly of such challenges, all the related
departments on the same floor gathered acrossboundaries and worked closely to surmount theseissues, which gave us tremendous confidence inourselves.

Toyota Industries’ Engine Production

61

Offering New Clean Diesel Engines with Significantly Enhanced Environmental Performance to Customers around the Worldbe regarded as a power train that can meet the highstandards required for installation in TMC’s Land Cruiser andIMV vehicles.
For the development of the GD diesel engine, wedrastically revolutionized the engine structure not only torespond to emissions standards in Europe, Japan, Asia,
South America, Oceania and other regions but also torealize superior performance in such properties as fuelefficiency, low speed torque, quiet operation and reliability.
As for the turbo fitted on the engine, respective members of
the engine and turbo development projects shared targets
and undertook tasks through close communication on eachother’s development status.
Primary concerns regarding diesel engines include noiseand vibration as well as particulate matter (PM) and othersubstances of concern included in emissions. The GD diesel
engine, however, not only offers a powerful driving
experience representative of diesel-powered vehicles but
also features improved environmental performance, and weexpect this engine will demonstrate excellent
competitiveness in the future global market.

Group manager0(FY) 54

2

Newly developed GD diesel engine

New turbocharger

33

Special Feature

2Offering New Clean Diesel Engines with Significantly Enhanced Environmental Performance to Customers around the Worldof passenger cars, we undertook development while
seeking advice from the engine development team how to“spice up” the turbo, which enabled us to gain yet anotherinvaluable experience and knowledge.
Our development team was responsible primarily forimproving the variable nozzle vane, which significantly
contributes to better performance of the turbo, andreviewing the aerodynamic design. These achievements
made it possible to realize the world’s top level in terms ofcompact size, high efficiency and wider flow range of theturbo. In the commercialization stage of the turbo, we
launched a Company-wide project and leveraged ourbroad-ranging technologies and know-how, including thoseof the Engine Business as well as compression andmachining technologies of the Car Air-ConditioningCompressor Business. In addition, we applied technologies
accumulated by the Engine Business and completed an
optimum turbo that provides superior cost performance for
the GD diesel engine.
An even more meticulous machining precision isrequired for the production of turbos compared withengines. As such, we sought the cooperation of our
Production Engineering Development Center to enablein-house production. The center has been responsible forthe development of production equipment for car airconditioning compressors, which requires extremely precise
machining technologies, and the collaboration enabledmass production of high-quality, high-performance turbos.

Comments from Turbo Developers ManabuIshikawa

Project leader(T Project, Engine Div.)

Hiromu Iwata
Working leader

We spent enormous efforts in the design of the variable
nozzle, which affects the basic performance of the newturbo. The nozzle plays a major role in adjusting the flowof emissions to the rotating wing depending on theoperating condition of the engine and in realizing highefficiency of the turbo. However, optimizing the nozzle
for the engine itself was a big challenge. While changes
in the turbo design would have an impact on the enginesystem, changes in the engine would affect the turbo
structure. To address this issue, we exhaustively
discussed matters by leveraging the advantage ofdeveloping both the engine and turbo, so we all had agreat sense of accomplishment when we were able tocome up with the best possible solution. Building on
this experience and knowledge, we will aim for thedevelopment of next-generation turbos, including thosefor materials handling equipment.

Comments from Turbo Production Engineer(Production Engineering Dept., Engine Div.)Katsushige
Takamatsu
Working leader

The most difficult challenge in the production of the newturbo was balancing high quality and low cost inaddition downsizing. To provide products whose quality
is competitive with leading turbo manufacturers, weestablished a production line by utilizing ourmanufacturing expertise and incorporating new ideas.
Particularly crucial was the machining of the wing, forwhich members from such departments asdevelopment, production engineering, production andquality assurance worked as a team to achieve highmachining precision. By leveraging our past experiencein the production of lift truck turbos, we repeatedly
discussed with members of the development
department how to balance machining precision withproduction efficiency, thus successfully establishing amore efficient production line.

Creating a Structure to Deliver Appealing
Diesel Engines to Customers around the WorldIn November 2014, we announced the agreement of thegradual integration of development and production of diesel
engines, which have been carried out jointly with TMC. The
aim was to efficiently strengthen the competitiveness ofdiesel engines by consolidating functions undertaken byboth companies and optimally allocating resources.
We will strive to offer appealing automotive and industrial
diesel engines that possess even more superior quality,including higher environmental performance, by promoting
development efficiency, bolstering cost competitiveness,further enhancing specialization of the Engine Business andhoning 3E (Energy, Environmental protection and Ecologicalthinking) technologies.
We will aim for the growth of our Engine Business bysolidifying the development and production foundations built
by the launch of new diesel engines and turbos, thereby
contributing to the realization of an environmentally friendly
society.
Assignment of Automotive Diesel Engine Production in the Toyota Group
Models in which Toyota Industries isinvolved from the development stage

L: Displacement

L

3.0L

VD

4.5L

HZ

4.2L

KD
GD

3.0L
2.5L
2.8L
2.4L

Toyota Industries

GD

3.0L
2.5L
2.8L
2.4L

ND

1.4L

KD

＊AD

2.2L

ND

1.4L

B

3.7L

KD

3.0L
2.5L

Daihatsu

Toyota* TMIP Joint venture in Poland established by TMC and Toyota Industries

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Toyota Industries Report 2015