2005 Corolla Verso DPL
1. Abridged version
At a glance
- Corolla Verso receives the new Toyota 2.2 D-4D diesel engine of the Avensis in two versions:
- D-4D 180: a 177 DIN hp (130kW) clean power with Toyota D-CAT, the most powerful and cleanest diesel engine of the segment.
- D-4D135: a 136 DIN hp (100kW) 2.2 D-4D, which marks a major improvement over the outgoing 116 DIN hp 2.0 D-4D
- All-aluminium construction and segment first use of Aluminium alloy cylinder block
- D-4D 180 engine features the lowest compression ratio of the segment (15.8:1) and also adopts ceramic glow plugs and piezoelectric injection system
- Top-class NVH levels
- Refined, fuel efficient and compact new 6-speed manual transmission
- The new 2.2 D-4D engines to be on sale across Europe as from October 2005
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 class-leading 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 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 super-green, 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- in just 9.0 seconds, before reaching a top speed of . 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 ( 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 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 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.
With its exceptionally compact structure, a mere 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.