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Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Model Outline
for Technician
Engine
U660E Automatic Transaxle Suspension and Axle Brake Brake Control System Tire and Wheel Steering
Chassis
Body
Body Electrical
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
U660E
3
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
5th
6th Reverse Differential Gear Ratio*1 Fluid Capacity*2 [Liter (US qts, Imp. qts)] Fluid Type
*1: Counter gear ratio included
0.713
0.608 4.148 3.935 6.54 (6.91, 5.76) TOYOTA Genuine ATF WS
*2: Differential included
Model Outline
for Technician
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2 planetary gear units are used Number of planetary gear unit, clutch and one-way clutch is reduced from U151E
The pump impeller and turbine runner portions have been made narrower Split piston for Clutch C2 that acts in the pull direction Compact and high-flow rate linear solenoid valve (SL1, SL2, SL3 and SL4) controls the engagement elements by directly Hydraulic Portion 3 ATF pressure switches are located in the output fluid passages of SL1, SL2 and SLU A felt type oil strainer is used Overflow plug for ATF adjustment TCM is mounted on the transaxle Hall IC type speed sensor (NT & NC) is used Clutch to clutch pressure control is operated at 2 3 4 5 6 shift change Powertrain cooperative control ensures excellent start-off performance, and realizes the deceleration which responded to the drives intension Lock-up clutch control & flex lock-up clutch control operation range is increased The curvature of the differential case opening is enlarged to moderate the stress concentration
Control
Other
5
Model Outline
for Technician
Engine
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U660E
U151E
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Planetary Gear Unit Number of planetary gear unit, clutch and one-way clutch is reduced from U151E
U660E
F1 C2 C1 C0 C2 B2 B3
U151E
B1
B1 F1 B2 C1
C3
F2 B3
Model Outline
for Technician
Engine
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Torque Converter The pump impeller and turbine runner portions have been made narrower
Narrowed
U660E U151E
Transaxle Type Torque Converter Type Stall Torque Ratio U660E 3-Element, 1-Step, 2-Phase 1.78
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Torque Converter Please make sure to check the installation condition of torque converter after you install
After the torque converter installation
Difficult to install
Narrowed
U660E U151E
B
Model Outline
for Technician
Engine
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Body
Body Electrical
Clutch Piston for C2 Split piston that acts in the pull direction
Split Type Piston
Spring
10
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Linear Solenoid Valve (SL1, SL2, SL3 and SL4) Compact and high-flow rate linear solenoid valve controls the engagement elements by directly
U660E
U151E
Linear Solenoid Valve
Line Pressure
Brake
Brake
Line Pressure
11
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
ATF Pressure Switch 3 ATF pressure switches are located in the output fluid passages of SL1, SL2 and SLU
Lower Valve Body
SLU
SL2
SL1
12
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Speed Sensor (NT & NC) Hall IC type speed sensor is used
Counter Gear Speed Sensor (Hall IC Type)
13
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Oil Strainer
Oil Pan
14
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Differential Case The curvature of the differential case opening is enlarged to moderate the stress concentration
: Tensile Stress : Compressive Stress
Large Curvature
15
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
16
Model Outline
for Technician
Engine
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Body Electrical
Automatic Transaxle Compensation Code Automatic transaxle compensation code (60-digit) on the QR label
QR Label
17
Service Point
Model Outline
for Technician
Engine
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Body Electrical
Automatic Transaxle Compensation Code After the following parts replacement, perform the A/T CODE SET or the ROAD TEST to improve shift shock
Replacement Parts Before the replacement READ A/T CODE O After the replacement SET A/T CODE O*1 O RESET MEMORY (O*2) (O*2) O O
ROAD TEST
O O O O O
TCM Automatic Transaxle Valve Body Assembly Shift Solenoid Valve (SL1 and SL2) Shift Solenoid Valve (SL3 and SL4)
*1: When the transaxle compensation code cannot be read from previous TCM, input the 60digit compensation code from the QR label on the current automatic transaxle *2: When SET A/T CODE is performed, the compensation code value learned by driving is also cleared
18
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Read Compensation Code)
19
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Read Compensation Code)
20
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Read Compensation Code)
21
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code)
22
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code)
Input
Open
23
Service Point
Model Outline
for Technician
Engine
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Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code)
(15 digits x 4 times) Input
123451234512345
Next
Open
24
Service Point
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code)
25
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Control Clutch to Clutch Pressure Control Line Pressure Optimal Control Powertrain Cooperative Control Shift Timing Control Lock-up Timing Control Flex Lock-up Clutch Control
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
TCM
ECM
SL1
C1
SL2
C2
SL3
B1
SL4
B3
Line Pressure
27
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Engine Output
Time
28
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Powertrain Cooperative Control The gear position during accelerator pedal OFF is determined by the drives pedal operation
[Deceleration Force Control]
: Sudden accelerator pedal operation
: Slow accelerator pedal operation
Gear Position
3rd
4th
Model Outline
for Technician
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Powertrain Cooperative Control Excellent response and shift shock reduction are achieved
[Transient Shifting Control] Drivers desired drive force Accelerator Pedal Operation Drivers desired drive force is achieved
ECM
ETCS-i Control ESA Control
TCM
Drives Solenoid Valve
Automatic Transaxle
30
Model Outline
for Technician
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Chassis
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Body Electrical
Lock-up Timing Control & Flex Lock-up Clutch Control Operation range
[Lock-up Timing Control] Gear 1st 2nd 3rd 4th 5th Position or Range D or S6 X S5 X S4 X [Flex Lock-up Clutch Control] Gear 1st 2nd 3rd 4th 5th Position or Range D or S6 X * * S5 X * * S4 X *
6th
6th
: Available X: Not available : Not applicable *: Flex Lock-up also operates, when the vehicle is decelerating
31
Model Outline
for Technician
Engine
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Body Electrical
Coast Downshift Control This control maintains sufficient engine speed and keeps fuel cut control operating for as long as possible
Fuel Cut Control ON
Fuel Cut Control OFF With Control Fuel cut time is expanded Without Control
Engine Speed
6th 5th
to 5th
to 4th
to 4th
to 3rd
32
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Multi-Mode Automatic Transmission Initial shift range from D to S is S4 or S5 range It is selected depending on the vehicle speed
- Default Shift Range -
P R N D 5 S
S4 P
S5
Vehicle Speed
R
N D
+
S
Shift Pattern
33
Model Outline
for Technician
Engine
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Multi-Mode Automatic Transmission When holding the shift lever to + position 1 second or more, the shift range is shifted up to S6 range
S1 S4 S5
S2
S6
R N D
6 S
S3
Hold 1 sec. or more
R
N D
+
S
Shift Range
S6 (D) S5 S4 S3
Usable Gear
6th 5th 4th 3rd 1st 1st 1st 1st
Shift Pattern
34
S2
S1
2nd
1st
1st
Model Outline
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Function Shifting to only either the 1st or 3rd gears is allowed. The counter gear speed is detected through the signals from the skid control ECU (speed sensor signals). Shifting between the 1st to 4th gears is allowed. Shifting between the 1st to 4th gears is allowed. When the vehicle is being driven in 6th gear, the transaxle is fixed in 6th gear. When being driven in any of the 1st to 5th gears, the transaxle is fixed in 5th gear.
CAN Communication Shifting to only either the 1st or 3rd gears is allowed. Knock Sensor Shifting between the 1st to 4th gears is allowed.
Solenoid Valve SL1, The current to the failed solenoid valve is cut off and control is SL2, SL3 and SL4 effected by operating the other solenoid valves with normal operation
35
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Trouble Area Input Turbine Speed Sensor (Hall IC Type) Counter Gear Speed Sensor (Hall IC Type) ATF Pressure Switch 1 ATF Pressure Switch 2 ATF Pressure Switch 3 Solenoid Valve SL4
P0791
P0872 P0873 P0877 P0878 P0989 P0990 P2808 P2810
36
Service Point
Model Outline
for Technician
Engine
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Body Electrical
Inspection ATF Inspection Procedure (No level gauge (dip-stick) and filler tube)
Check Items Visually check for ATF leaks of the following areas - Overflow Plug - Oil Seal - Each Case Join, etc
NOTE: If there is no ATF leak from transaxle, check of the ATF level is no required
37
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Refill Plug
2.
3.
4.
5. 6. 7.
Service Point
Model Outline
for Technician
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Chassis
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Body Electrical
Automatic Fluid (ATF) TOYOTA Genuine ATF WS is used for fuel economy by reducing its viscosity
Thick
ATF Viscosity
T-IV
WS
ATF Temp.
High
39
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Removal and installation of oil pan Removal and installation of drive shaft Removal and installation of valve body Removal and installation of torque converter Replacement of oil cooler Repair of oil leakage
40
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
P R N
+ D S -
D N
6 secs. or more
41
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
P R N
+ D S -
D N
6 secs. or more
42
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
5.
6. 7.
43
Model Outline
for Technician
Engine
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Body
Body Electrical
Suspension MacPherson strut type front suspension Torsion beam type rear suspension with toe-correct function
44
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Tread
Camber Toe-in
[mm (in.)]
[degree] [mm (in.)]
1,585 (62.4)
-1 30 3 (0.12)
45
Brake
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Specification
Master Cylinder Brake Booster Type Diameter Type Tandem 22.2 mm (0.87 in.) Single
Size
Caliper Type Wheel Cylinder Diameter Rotor Size (D x T) Pad
10.5 in.
AX63 63.5 mm (2.50 in.) 296 mm x 28 mm (11.65 in. x 1.10 in.) PV565H
Front Brake
Caliper Type
Rear Brake Wheel Cylinder Diameter Rotor Size (D x T) Pad Parking Brake Type Drum Inner Diameter
ZOH43
42.86 mm (1.69 in.) 298 mm x 12 mm (11.73 in. x 0.47 in.) NS254 Duo servo 190 mm (7.48 in.) ABS with EBD, BA, TRC, VSC and Cooperative Control with EPS BOSCH With
Brake Control Function Skid Control ECU and Brake Actuator Manufacture VSC OFF Switch
46
Brake
Model Outline
for Technician
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Chassis
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Body Electrical
Brake Booster Single diaphragm type brake booster with a tie rod structure for weight reduction
47
Brake
Model Outline
for Technician
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Chassis
Body
Body Electrical
Aluminum
48
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Speed Sensor Speed sensor type has been changed from passive type to active type
Active Type (Semiconductor) Passive Type (Magnetic pick-up)
Coil
Magnetic Rotor
MRE
Rotor
Yoke
Magnet
New ALPHARD
Previous ALPHARD
49
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
1 2 MRE 4 3 + -
Output
Comparator
50
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
FL+
MRE
FL-
51
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Speed Sensor Signal output at extremely low speed rotation can be ensured
Active Type (Semiconductor) Passive Type (Magnetic pick-up)
No Detecting Vehicle Speed Vehicle Speed Time Sensor Output
Sensor Output
Time
52
Service Point
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
12V
FL- to GND
GND
53
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Cooperative Control with EPS In addition to the conventional VSC system, cooperative control with EPS is newly added to improve the vehicle posture control
V Bus No.1 Combination Meter ECM Main Body ECU Steering Angle Sensor Yaw Rate and Acceleration Sensor
Brake
Brake Actuator
54
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Cooperative Control with EPS EPS assist force is controlled to help driver handling during VSC system operation
When road surface resistance differs between both sides of wheels
Increase Assist Power
[Rear Wheel Skid Tendency]
Low High
Low High
Service Point
Model Outline
for Technician
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Inspection Mode Inspection mode turns off the TRC and VSC systems completely
within 30 seconds
within 15 seconds
Engine switch OFF P Range PKB ON
Brake
Brake
Brake
Depress twice
ON
Start engine
Depress twice
PKB PKB
Model Outline
for Technician
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Chassis
Body
Body Electrical
Off Set
Disc Wheel
33 mm (1.3 inch)
Design
57
Service Point
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Spare Tire Spare tire carrier cannot accommodate ground tire Wrap punctured tire in wrapping sheet, and store it in luggage compartment
Wrapping Sheet
Wrap
58
Steering
Model Outline
for Technician
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Chassis
Body
Body Electrical
[Specification]
Type Gear Ratio (Overall) No. of Turns Lock to Lock Vehicle Speed Sensing Type 16.5 3.30 Steering Column Assembly Brushless Motor with Rotational Angle Sensor Reduction Mechanism Hall IC Type Torque Sensor
Rack Stroke
59
[mm (in.)]
143.8 (5.66)
Steering
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
System Diagram
Hall IC Type Torque Sensors Reduction Mechanism
Brushless Motor (Resolver Type Rotational Angle Sensor included) V Bus No.1
DLC3
DTC
60
Steering
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Steering Column and Brushless Motor DC brushless motor with resolver type rotation angle sensor which reduces motor speed via worm gear and transmits it to the column shaft
Motor
[Motor]
Wheel Gear Rotation Angle Sensor Rotor
Stator
Output Shaft
Column Shaft
61
Steering
Model Outline
for Technician
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Chassis
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Body Electrical
Torque Sensor Torque sensor using two hall ICs consists of a multipole magnet mounted on the input shaft, and a yoke mounted on the output shaft
Motor Output Shaft Yoke
[Torque Sensor]
Input Shaft
Torsion Bar
Output Shaft
Column Shaft
62
Steering
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Torque Sensor (detection of twisted angle of torsion bar) Hall ICs detect the direction of the magnetic flux which passes through inside of the yoke [When steering turned to Right]
Input Shaft Magnetic Flux Left Turn (+) Hall IC1 Output Voltage (V) Right Turn
Hall IC2
(-)
Twisted Angle of Torsion Bar (deg) Yoke Output Shaft : Hall IC1 Signal : Hall IC2 Signal : Neutral Position
63
Steering
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Torque Sensor (detection of twisted angle of torsion bar) Driven straight: Magnetic flux does not through in yoke Turning: Detects the direction of the magnetic flux
[Driven Straight]
Input Shaft
[Turn to Left]
Input Shaft
[Turn to Right]
Input Shaft
Output Shaft
Output Shaft
Output Shaft
64
Steering
Model Outline
for Technician
Engine
Chassis
Body
Body Electrical
Function
Calculates the assist current from the steering torque value and the vehicle speed, and actuates the motor Improves the starting movement of the motor when the driver starts to turn the steering wheel During the short interval between the time the driver fully turns the steering wheel and the wheels try to recover, this control assists the recovery force Regulates the amount of assist when the driver turns the steering wheel while driving at high speeds, thus damping the changes in the yaw rate of the vehicle body Estimates the motor temp. based on the amperage and the current duration . If the temp. exceeds the standard, it limits the amperage to prevent the motor from overheating Controls EPS system in order to facilitate the driver to operate the steering in a direction that stabilizes the vehicle during VSC operating Limits the operation of the electric load when the battery voltage decreases
Damper Control
System Overheat Protection Control Cooperative Control with EPS EPS Electric Load Control
65
Steering
Model Outline
for Technician
Engine
Chassis
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Body Electrical
EPS Electric Load Control In order to prevent reduction of EPS assist force, when battery voltage becomes low, the operation of rear window defogger is limited
Battery Voltage
V Bus No.1
OFF
Limitation Demand
66
Steering
Model Outline
for Technician
Engine
Chassis
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Body Electrical
Diagnosis and Fail-safe When malfunction occurs in EPS system, power steering ECU controls following control: Turns on P/S warning light and fail-safe operation
DTC No. C1511 / 11 C1512 / 11 C1513 / 11 C1514 / 11 C1515 / 15 C1516 / 16 C1517 / 11 C1521 / 25 C1522 / 25 C1523 / 24 C1524 / 24 C1525 / 17 C1526 / 18
67
Detection Item
Torque sensor malfunction Torque sensor power supply abnormal Torque sensor zero point adjustment undone Torque sensor zero point adjustment incomplete Torque hold abnormal
Motor malfunction
Illuminate
Rotation angle sensor output initialization undone Rotation angle sensor output initialization incomplete
Illuminate Illuminate
Steering
DTC No.
Model Outline
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Body Electrical
C1551 / 25
C1552 / 22 C1554 / 23 C1555 / 25 C1581 / 26 U0100 / 41 U0129 / 42
Illuminate
Illuminate Illuminate Illuminate Illuminate
68
Steering
Model Outline
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Diagnosis and Fail-safe When the system detects the malfunction, system enters to fail-safe mode as follows
Fail-safe Operation Items Torque sensor malfunction Motor overcurrent Motor short (Including drive system malfunction) Power steering ECU malfunction
Motor overheating Power steering ECU internal temperature sensor malfunction Vehicle speed signal malfunction Engine speed signal malfunction Power supply voltage malfunction
69
Service Point
Model Outline
for Technician
Engine
Chassis
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Body Electrical
(Steering)
Initialization and Calibration Perform the initialization and calibration of EPS system in the following cases using the intelligent tester
Assist Map Writing Power steering ECU replaces Steering column assembly replaces Steering effort differs between turning left and right O Rotation angle Torque sensor zero sensor initialization point calibration O O O O
NOTE: Initialization and calibration cannot be performed when the DTCs (C1516 and C1526) are stored
70