2007

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2007 IMPORT TECH REPORT

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t’s a huge year for import car nameplates. A number of “crossover” vehicles have been added to the regularly scheduled model replacements. We noted last year the arrival of the econocars (Toyota Yaris, Honda Fit and Nissan Versa); this year we’ve had a chance to study them. Without further ado, here’s what’s happening on the import front.

Toyota/Lexus The new Lexus LS 460 is brand-new, including the powertrain. And when the LS 600h hybrid comes out shortly, it will have an even higher level of technology. 18

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The 4.6L V8 is not a bigger 4.3L; it’s all-new, with both direct fuel injection and port injection, the dual system introduced last year on the 3.5L V6 in the Lexus IS 350. Port injection tunes the air/fuel mixture for cold starts and part throttle operation, while eliminating use of multiple airflow paths and idle butterfly valves that produce restrictions. In fact, there’s an air intake split with separate air filters. The 4.6 V8 produces 380 hp and 367 ft.-lbs. of torque (vs. 278/312 with the 4.3 V8). Electronic/electric intake cam phasers (variable valve timing) are a precise but expensive approach, and the first production application of that technology. Less-critical exhaust VVT

Background photo montage: Harold A. Perry

BY PAUL WEISSLER There’s lots to cover on the import service front, with a wide assortment of new models and attendant technological advances, from all corners of the globe.

Audi Q7

Acura RDX

Mercedes-Benz S-Class

Lexus LS 460

Infiniti G35

Nissan Altima

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2007 IMPORT TECH REPORT

Electric Camshaft Phaser

The air intake (at right) feeds through dual air filters on the Lexus LS 460 V8.

which means when the driver brakes to a stop, he can push a button on the steering wheel to hold pressure in the lines so the car doesn’t move (or roll on a hill). Stepping on the gas pedal releases the pressure. Toyota’s Yaris econocar, previously sold here as the ECHO, is powered by a 106-horse, 1.5L chain-drive fourcylinder mated to a five-speed manual or four-speed automatic transmission. The brakes are ventilated discs in front, drums in the rear. Power steering is electric, which is what you’ll find on the competitive models, too. It not

Camshaft Actuator

Pump Cam

No. 2 Cylinder Cams

No. 4 Cylinder Cams

No. 6 Cylinder Cams

No. 8 Cylinder Cams

Right-Hand Exhaust Camshaft Oil-Pressure-Controlled Phaser The LS 460 V8’s intake cam phaser features electronic/electric operation. The exhaust camshaft phaser is a conventional oil pressure-controlled type.

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Illustration courtesy Lexus

Right-Hand Intake Camshaft

only eliminates the pump and hydraulic lines, but improves fuel economy. However, be aware that the Yaris’ steering gear contains a torque sensor, which has to be initialized to zero if the steering gear, steering wheel or steering computer is replaced, or if the sensor goes out of calibration. (A difference in steering effort from left to right is a common symptom.) No Toyota scan tool software? A shop manual procedure using a jumper wire is available. The new Camry continues with the 2.4 Four and a 268hp port-fuel injected version of the 3.5 V6 in the Lexus IS. The transaxle is a six-speed, also with planetary and Ravigneaux gearsets, but without all the clutches and brakes that produce eight ratios, such as in the Lexus LS 460. The exterior solar-blocking glass on the Camry reportedly keeps out over 90% of ultraviolet and infrared light. This reduces the a/c cooling load, which should improve fuel economy. The Camry’s a/c system also includes an ion generator called the Plasmacluster Generator to improve interior air quality. It uses a high-voltage device that emits a slight sound. Dust will accumulate at the driver’sside register. Clean it with the blower off, using a wiping cloth; never spray solvent into the register. The hybrid Camry is powered by the 2.4L Four, with these changes: Intake valve timing is retarded, the piston shape is changed, the radiator fan is a higher performance version, there’s no conventional starter or alternator, of course (the hybrid system has two motor-generators that serve these functions), the gas tank is steel and the catalytic converter and exhaust manifold are made specifically for the hybrid application. The a/c is operated by an electric motor so it can cool even with the engine stopped, and an auxiliary electric water pump also is used. The hybrid 2.4 develops 147 hp, vs. Photo courtesy Lexus

continues with oil pressure phase control. Direct-acting buckets were replaced by roller rocker arms with hydraulic adjusters, a lower-friction system that never requires adjustment. The oil filter is Toyota’s cartridge type, in a housing with an oil drain plug, as introduced on the 2006 Lexus IS 250 AWD. Inserting a drain pipe (packaged with the OE cartridge) opens a spring-loaded valve for the oil to flow out. An eight-speed automatic tranny upstages Mercedes’ seven-speed. The gearing setup, however, is just a planetary gearset (which provides two speeds), followed by a 4x multiplier from a Ravigneaux gearset (basically two planetary gearsets melded into one, with just one ring gear). Other transmissions have used this setup for four- and six-speed automatics, but it takes four clutches, two disc brakes and one overrunning clutch to get eight gears. Power steering is all-electric and with optional air suspension, variable gear ratio steering is used. This makes the ratio “faster” as the steering wheel is cranked into a turn. The brake system has a hold feature,

2007 IMPORT TECH REPORT 158 for the regular Camry, but with the 245-volt battery pack and the electric motor, horsepower total is 192. The Camry hybrid has a separate liquid cooling system for the two motor-generators and the inverter electronics, plus a dedicated radiator integrated with the engine radiator.

which requires initialization—after the battery is disconnected, of course, but also if the window is partly When opened and/or closed many Draining Oil times without a full closure. Element The 2007 Altima, on a new “world” platform shared with Renault, has the fourthgeneration 3.5L V6 (80% Filter Cap new parts), including VVT on intake and exhaust as an Nissan/Infiniti option, with horsepower up Nissan has three new frontfrom 245 to 270. The former Drain Pipe O-Ring drive sedans—Versa, Sentra two-belt accessory drive was and Altima—and Infiniti’s changed to a single serpenDrain Plug O-Ring brand-new G35, the car that tine belt. V6 problems with proved that a great-hantorque steer were solved by dling, more powerful com- The oil filter housing drains when the plug is removed and lowering the engine mountpetitor to the BMW 3 Series the drain pipe is inserted on the Lexus LS 460. ing 1⁄2 in. and positioning the could come from Japan. front axle shafts more paralThe Altima continues with the lel to the ground. require narrow-diameter spark plugs. 2.5L Four, but a new family of smallThe 2.5 was freshened up to reAlthough all the Nissan Fours are er Fours provides a 120-hp 1.5L for the highest in their class in horsepowduce NVH, using 100 new parts (out the Versa and a 147-hp 2.0 for the er, what sets them apart technologiof about 500 total). Sentra. Although the engines are simcally is the optional continuously variAltima also gets a hybrid model. ilar in shape and share some bolt-on able transmission (CVT) from NisNissan buys Toyota’s hybrid system parts, the 1.5 is much smaller and is san’s JATCO affiliate. It improves fuel and integrates it with a modified ver39 lbs. lighter, at 209 lbs. They have economy and acceleration. sion of the Nissan 2.5 Four. different bore centers and separate The Infiniti G35 sedan got a major Although an econobox, Versa is an assembly lines. Nissan gets the needoverhaul (expect similar changes upscale model in Japan, which exed volume for each by sharing enwhen the coupe comes out in the plains why it’s larger than the Fit and gines with Renault. The compact despring). The platform is second-genYaris. It also offers an express-up signs have relatively large valves that eration front midships, and the 3.5 V6 power window on the driver’s side, is rated at 306 hp, 268 ft.-lbs. of torque. The 2006 base engine was ratB A ed at 280/270, although a high-performance manual transmission model with intake/exhaust VVT was rated at 298/260. The new engine is rated according to a revised testing standard, so 2007 horsepower improvements are likely to be even greater. Internal changes also boost the engine redline 1000 rpm, to 7600. The G35 has optional four-wheelactive steering. Front steering is variable ratio—from 12:1 up to 18:1. The motor-controlled rear steering is modest (under 1°), but makes a noticeable difference in hard cornering. It’s similar to the system used last year in the Infiniti M series. HID (high-intensity discharge) headlights in the G35 sedan are in a sculptured housing with a computerThe Lexus eight-speed automatic trans has a planetary gearset (A) followed by a Ravigneaux gearset (B), plus clutches and brakes to produce eight ratios. controlled internal motor drive that Photo courtesy Toyota

Illustration courtesy Lexus

Oil Filter Case

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pivots the outboard light into turns. The rear taillamps incorporate an array of LEDs. All-wheel-drive with traction control, a system also used on the M35 and FX, is an option. Electronic stability control is standard on all G35 models.

Mercedes-Benz In the Mercedes S-Class and CLClass, radar-based adaptive cruise control is integrated with the Pre-Safe collision avoidance system. Pre-Safe is integrated with Brake Assist, with additional radar sensing, to add braking

Illustration courtesy Toyota

The S-80 transverse front-drive, Volvo’s flagship vehicle, finally gets an allnew offering. It may look like the previous model, but it’s on a new platform and is loaded with new technology. The 60° Yamaha 311-hp V8 is a pickup from the XC-90, as is the new 235-hp, 3.2L in-line Six, no relation to the old timing belt-driven 2.9 I-6. Although designed by Volvo, the 3.2 I-6 is made in England and will go to Ford’s Jaguar and Land Rover divisions. The 3.2 camshaft is flywheel-end chain-driven with intake and exhaust VVT, and variable intake lift by locking in a high-lift lobe at high rpm. In addition, the air intake system has two flap valves that change the lengths of the airflow paths. Volvo mates the 3.2 I-6 to a sixspeed automatic, so there’s a premium on minimizing engine length. The I-6 is 25 in. long—just .1 in. longer than the I-5, which has a timing belt. Chain drive helps, but also the vibration damper (a viscous-fluid filled type) is internal and a serpentine belt drive is positioned at the rear with the power steering pump and a/c compressor mounted in an open area above the transmission. The alternator is on the side of the engine, directdriven by a shaft off the camshaft. Oil change tip: Remove the oil filter element first, to allow a springloaded valve to open, so oil in the filter housing drains into the oil pan and out the drain plug hole. The V8 is combined with AWD only, to prevent torque steer.

TS

TC

The electric power steering torque sensor on the Yaris can be initialized at the underhood diagnostic connector, with special jumper wire procedures for TC (computer), TS (sensor) and CG (ground) terminals.

power in case of an impending crash—up to 40% of the maximum possible brake force. Mercedes got a temporary federal exemption to use flashing rear brake lights during any brake assist situation, to alert other vehicles. The flashing brake lights also go on if the electronic stability system detects low-friction road surfaces, such as ice. Mercedes’ new infrared night vision doesn’t just produce a vague outline, but with projectors bathing the

road ahead in infrared light, produces real black & white images. The monster twin-turbo intercooled 6.0L V12 is rated at 510 hp and 612 ft.lbs. of torque, and it’s at the top for the S-Class and CL-Class coupe. A near match is the naturally aspirated AMG high-performance 6.3L V8, rated at 507 hp, but “only” 465 ft.-lbs. of torque. Also available is the 5.5L four-valve V8 rated at 382 hp/391 ft.-lbs. The R-Class continues with the old three-valve 5.0 V8, rated at a modest 302 hp/339 ft.-lbs.

Photo: Paul Weissler

Volvo

CG

Versa’s engine compartment has a 1.5L version of the new family of fourcylinder engines. Sentra receives a more powerful 2.0L version.

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2007 IMPORT TECH REPORT The high-volume E-Class still offers the four-valve 3.5L V6 (268 hp/358 ft.-lbs.), and the 5.5L V8 and the 6.3L AMG V8. But the really interesting engine is the new E320 V6 diesel. The number notwithstanding, it displaces just 3.0 liters and replaces the 3.2L in-line diesel. The new diesel, which also will be offered in the R-Class, gets a bit more horsepower (208 vs. 201) with less displacement, and its 400 ft.-lbs. of

burns off particulates, which drop off the filter into a bin, which a technician will have to clean out periodically. If the EPA approves, further down the road is likely to be urea solution injection into the SCR catalyst, which would enhance the SCR catalyst performance, necessary for 2009 regulations.

Photo: Paul Weissler

Hyundai

Each member of the Nissan fourcylinder family is very compact, with large valves. The spark plug as shown is a narrow-diameter design.

torque comes in at 1600 rpm. It runs on the new ultra-low-sulfur diesel fuel only, and relies on a multistep emissions control system: Piezoelectric injectors produce multiple pulses per injection and an exhaust system particulate filter and selective catalyst reduction (SCR) filter do the biggest job of reducing NOX (there’s also an improved DeNoX three-way cat). The system, branded Bluetec as a symbol of low emissions, also is being used by BMW and VW/Audi in Europe. At intervals, an incineration process

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There are three new Hyundai models for 2007, all with V6 engines with variable intake valve timing. Two are “short list” nominees for the prestigious North American Car and Truck of the Year awards—the Elantra and Santa Fe, respectively. The “truck” nomination notwithstanding, Hyundai’s midsize Santa Fe moves from an SUV platform to a brand-new carlike crossover platform. Base engine is the 2.7 V6, upgraded with VVT (horsepower rises from 170 to 185). Gone is the 3.5L V6, an iron-block engine that produced just 200 hp. It’s replaced by the Sonata’s aluminumblock 3.3 V6 that develops 42 more horses. Drivetrain is tri-mode—frontdrive, AWD and AWD-Lock. Hyundai’s Entourage is a minivan, with an interior that’s a whisker larger than the import-leading Odyssey, and powered by the Azera’s 250-hp, 3.8L V6. The Tiburon sporty car is restyled and adds an optional 2.7 V6 to the 138hp, 2.0 Four, a reworked cast-iron block engine also used in the Elantra. Speaking of the Elantra, Hyundai’s “B-class” car is all new for 2007 and demonstrates determination to be class-leading. Cubic footage for the interior is 97.9; for the trunk, 14.2. The 2.0 Four that’s shared with the Tiburon was substantially reworked, with low-friction rings, more sophisticated computer control and hydraulic engine mounts. Horsepower drops modestly from 138 to 132 in a PZEV version sold in California. Underhood, there’s no power steering pump (power steering is all-electric), which improves accessory-end serviceability and fuel economy. Along with other changes, including to the tires and transmission, the highway number for automatics is up 4 mpg to match the manuals (36 mpg, to go with 28 city).

If the chart at right is missing, please circle #40 on the Product Information Card on page 51.

2007 IMPORT TECH REPORT Elantra is the only B-class car with four-wheel discs/fourchannel ABS as standard equipment.

Illustration courtesy Mercedes-Benz

Photo courtesy Volvo

there’s not an electronic module in sight. The propeller shaft drives one oil pump, the rear axle drives another and the differential pressure modHonda/Acura ulates application of a multiHonda’s Fit is powered by a disc clutch pack in the torque 109-hp, 1.5L single overheadtransfer coupling. cam four-cylinder with chain The Acura line adds the drive. It has all of Honda’s soRDX, a new, smaller SUV apphisticated engine controls, parently based on the same including VVT and lift (using platform as the CR-V, but Honda’s two-rocker system), with Acura’s first turboand an electronic throttle charged/air-to-air intercooled with accelerator pedal sensor. engine. It’s a 2.3L engine that The Fit’s on-board diagnosproduces 240 hp and 260 ft.tics include Honda’s no-troulbs. of torque, and although ble-code algorithm to detect a the bore and stroke are carbonized throttle body. 87x89mm, the engine is a verWith your scan tool connectsion of the 2.4L DOHC used ed, run the engine at 3000 in the CR-V. rpm no-load until the radiator The turbo, which has a fan comes on. Then let the peak boost of 13.5 psi, is inteengine idle and check the Volvo’s new 3.2 I-6 must fit transversely, so its length has grated with the exhaust manithrottle position sensor, which been held to just .1-in. more than the I-5, thanks to the fold, which is bolted to the should read under 2.6°. If it rear camshaft chain drive, direct mount and gear-drive rear side of the transversely reads higher, the throttle of the alternator and novel rear accessory drive with belt mounted engine. It’s a varibody needs to be cleaned. able-flow design (like many for the power steering pump and a/c compressor. The engine block has a turbos), with a valve that partcoolant drain plug, which is partly hidlower torque strut mounted to the subly restricts exhaust gas flow at low rpm, den by the oil filter. Even with the plug frame and a transmission mount. The to accelerate flow to the turbo impeller, out and the radiator drained, it’s a tough torque struts are intended to reduce so it runs faster to reduce turbo lag. On cooling system to empty—almost 30% idle vibration and engine noises during cold starts, timing is retarded for emisof the coolant will remain in the system. acceleration. sions control, which also reduces engine Power steering is fully electrical/elecThe CR-V continues with its optional vacuum (a real problem for braking, tronic—no hydraulic pump or lines. all-mechanical Real-Time 4WD system; particularly at high altitude). So the car The CR-V sport/ute (and the mechanically similar Element) was reAdvanced DeNoX SCR Catalytic designed completely for 2007, including Catalytic Converter Converter the spare tire moved inside and the tailgate flipping up instead of opening from the side. The 2.4L dual overhead-cam Four remains the only engine, and although it’s up 10 hp to 166 (161 ft.-lbs. of torque), its biggest change is the switch from a cable to an electronic throttle and retuning for a flatter torque curve. The 2.4 is a long-stroke engine Oxidizing (87mm bore x 99mm stroke), which Catalytic Converter contributes to good launch. The engine mounting system also Particulate Filter has been completely changed. Instead of four lower mounts (including the This illustration shows the exhaust-gas treatment system of the E 320’s “Bluetransmission mount) to the body and tec” 3.0 diesel V6. The engine uses DeNoX (a special three-way catalyst), particsubframe, the 2007 model has an upulate filter and SCR (selective catalyst reduction) for emissions control, in adper front torque strut (with integrated dition to a conventional oxidation catalyst (far left). This system is designed for mount) attached to the body, a rear use with the new ultra-low-sulfur diesel fuel now available in this country.

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Photo: Paul Weissler

2007 IMPORT TECH REPORT

The 2.0 Four in the Elantra is now easier to service, thanks to the elimination of the power steering pump; an all-electric system is now used.

has an auxiliary vacuum pump connected to the brake booster. The opening above the Acura badge is functional; it’s the air inlet to the turbo. Acura’s latest Super-Handling AllWheel-Drive system, adapted from the RL, is standard on the MDX and RDX. Torque going to the rear wheels is distributed side-to-side according to demand. However, if the vehicle is in a turn, it speeds up the outside wheel to help pull the car through the turn, rather than apply the inside wheel brake.

option. This is the manuallike transmission with a dual clutch system that preselects the next gear, so simply engaging the other clutch executes the shift. Also optional are adaptive (swiveling) headlamps. The new Audi Q7 crossover is based on the Touareg platform, with a choice of direct-fuel-injected V6 and

V8 Audi engines. The base engine is the 3.6L V6, rated at 280 hp and 266 ft.-lbs. of torque. The 4.2 V8 is optional, rated at 350 hp/325 ft.-lbs. The Q7 has a basic Borg Warner AWD system, not an elaborate design with a two-speed transfer case. It’s all a crossover needs. The Q7 actually was the first vehicle out with blind spot detection, which it calls Side Assist. Radar sensors monitor the adjacent lanes behind the vehicle, and if there’s a car in one or both of them, a yellow light in the corresponding outside mirror lights up. If the driver puts on the turn signal for a lane change, the yellow light starts flashing as a more urgent warning that a vehicle is in that lane. Most significant for independent technicians, however, is the replacement of the “erwin.de” technical information website based in Germany with one built and operated for Volkswagen/Audi in the U.S. by Robert Bentley Publishers, which had been operating an independent site for German car technical information. The Erwin site required opening an account in advance, then selecting documents for download purchase, relying only on a table of contents. The new

VW brought back the Rabbit name for the Golf, and added the Q7 crossover to the Audi line. And there’s the new Eos, a hardtop convertible based on the Golf/Rabbit, but with a platform reinforced in many key places to maintain that vehicle’s splendid handling. Eight electrohydraulic cylinders operate the hardtop (25 seconds for a full cycle). The top also includes a power sliding glass sunroof. The base engine is the 2.0L turbo rated at 200 hp; the narrow-angle (single-head) 3.2L V6 rated at 250 ponies is an option. Although the six-speed manual transmission is standard, VW’s “direct-shift” automatic six-speed is an

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Illustration courtesy Honda

Volkswagen/Audi

The drain plug on the Honda Fit engine block is partly hidden behind the oil filter.

Other Import Nameplates Mazda introduces two crossovers for 2007. One is the CX-7 (two rows of seats), based on the Mazda 3 platform, and the MazdaSpeed 3 engine (2.3 Four direct-injection turbo, developing 244 hp, vs. 156 for the natuVacuum Hose With Vacuum Pump Check Valve

Illustration courtesy Acura

Filter

Electric Vacuum Pump

Screen capture: Paul Weissler

website—www.ebahn.com—gives you the same type of total access for VW or Audi, as the best of the factory websites, priced at $20 for three days for one car, $50 for three days. Although users of aftermarket service information systems will continue to use those sources for most repair data, the new VW/Audi site serves a number of special purposes. First, it supports J2534, the SAE standard for generic reprogramming of on-board computers. So if you’re using a J2534 Pass-Thru, you’ll find what you need on the new site. If a bulletin says reprogramming is required for a fix, the new website provides a link to the software, sold for an additional fee. Second, it provides trouble-code-guided diagnostics. If there’s a code, select it and you get a step-by-step illustrated sequence for troubleshooting. And the parts locator provides both photo and outline drawing to pinpoint the location.

VW/Audi ebahn.com website bulletin includes a Pass-Thru link as noted on the right side of the screen, for access to needed reprogramming software.

rally aspirated engine). The other is the CX-9 (three rows of seats), a Mazda-styled and ride/handling-tuned Ford Edge with the Ford 3.5L V6. Suzuki also has two new crossovers. The XL-7 is now Chevy Equinoxbased with the GM 3.6L V6. But that engine is being built by Suzuki itself and so has some specific tuning. The Brake Booster

Vacuum Hose With Intake Manifold Check Valve

Auxiliary Underhood Fuse/Relay Box

Brake Booster Pressure Sensor

PCM Underhood Fuse/Relay Box

Underdash Fuse/Relay Box

Data Link Connector (DLC)

The Acura turbo has an electric vacuum pump, so brake boost is available during low-vacuum conditions caused by high altitude and timing retard.

SX-4 is built on a modified Reno platform with an all-aluminum 2.0 Four (vs. the cast-iron block 2.0 in the Reno). It’s just 131⁄2 ft. long. Mitsubishi introduces an attractive new edition of the Outlander crossover, with an all-new VVT-variable lift 3.0L V6 rated at 220 hp and 204 ft.-lbs. of torque. The single OHC engine is Partial Zero Emission (PZEV) rated, and has the Premaircoated radiator that eats ozone. The engine mates to Mitsubishi’s first sixspeed automatic. Drivetrain is threemode-front-drive, AWD-Auto and AWD-Lock (although unlike others, it can vary torque transfer, favoring the rear wheels with up to 60% of available torque). The previous model was powered by a 2.4L Four, with another fourcylinder model being held off. Jaguar’s XK coupe and softtop convertible feature the pioneering all-aluminum monocoque (glued and riveted construction originally developed for the XJ sedan). The engine is the 4.2 V8, rated at 300 hp; a supercharged version delivers 400 horses. The power top may be soft, but at 18 seconds to open or close, it’s also quick. Visit www.motor.com to download a free copy of this article.

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