Model Outline for Technician Engine Chassis Body Body Electrical

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Model Outline for Technician Engine Chassis Body Body Electrical
Manual Transaxle
Automatic Transaxle
Brake
Brake Control System
Steering

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Model Outline for Technician Engine Chassis Body Body Electrical

Manual Transaxle
Shift Guide Plate
– It clarifies the position of the shift knob and enables
accurate shift lever operation
Neutral Position Shift Completed

Shift
Guide
Pin Select

Shift
Shift
Guide
Plate

Shift and Select Shaft

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Model Outline for Technician Engine Chassis Body Body Electrical

Manual Transaxle
Transmission Control Cable
– Cable length adjustment mechanism is used for the
transmission control select cable
Shift Lever

Shift Cable

Adjustment
Select Cable Mechanism

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Manual Transaxle)

Transmission Control Cable
– Adjustment of select cable
1. Move the shift lever to 3. Release the select cable
neutral position
Lock
Piece

Neutral

4. Install the end of the select cable

2. Disconnect the end of the 5. Lock the select cable

select cable

Release Lock

6. Check the shift lever operation

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Model Outline for Technician Engine Chassis Body Body Electrical

Automatic Transaxle
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

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Model Outline for Technician Engine Chassis Body Body Electrical

Automatic Transaxle
Multi-mode Automatic Transmission
– In the S mode position, the driver can select the
desired shift range by moving the shift lever to the
"+" position or to the "-" position

S Mode
Indicator

Shift Range
Position
Indicator

[Shift Program]
Shift
Usable Gear
Range
S4 (D) 4th 1st
S3 3rd 1st

S Mode Position S2 2nd 1st

S1 1st

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Model Outline for Technician Engine Chassis Body Body Electrical

Automatic Transaxle
Multi-mode Automatic Transmission
– “ + ” Position: Shift range is upped
– “ - ” Position: Shift range is downed
– Default shift range from “D” to “S” is S3

S4
“D”  “S”
S3

S2

S1
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Model Outline for Technician Engine Chassis Body Body Electrical

Automatic Transaxle
Transmission Control Cable
– Cable length adjustment mechanism is used to
improve serviceability

Adjustment
Mechanism
Shift
Lever

Transmission
Control Cable

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Automatic Transaxle)

Transmission Control Cable
– Adjustment
1. Apply the parking brake 4. Release the cable
Move the shift lever to N position
Lock
Piece
N

2. Disconnect the end of the cable

5. Install the cable to the retainer
6. Install the end of the cable
7. Lock the cable

Release Lock
3. Disconnect the cable from the retainer
8. Check the shift lever operation

10 Retainer
Model Outline for Technician Engine Chassis Body Body Electrical

Brake
Rear Disc Brake
– Built-in parking brake is used for rear disc brake
– Brake cylinder made of aluminum

Parking
Brake Cable
Aluminum
Made Brake
Cylinder

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Model Outline for Technician Engine Chassis Body Body Electrical

Brake
Rear Disc Brake
– Construction
Piston Push Rod
Check Ball

Operation
Lever

Input Shaft

Pad Nut Sleeve

NOTE: The inner structure of the brake cylinder for New COROLLA is slightly different
12 from the illustration
Model Outline for Technician Engine Chassis Body Body Electrical

Brake
Rear Disc Brake
– Parking brake operation

PKB OFF

PKB ON

Depth of the check ball

groove becomes shallow

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Model Outline for Technician Engine Chassis Body Body Electrical

Brake
Rear Disc Brake
– Adjustment operation (when pad is worn)
At Braking Turned & Moved

Pad is After
worn braking

Clearance

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Brake)

Rear Disc Brake
– Use the SST when adjust the protrusion amount of the
brake piston at installation

SST: 09960-10010
(09963-00400)

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Brake)

Rear Disc Brake
– Align the piston direction when the installation

90°

Protrusion
portion

Installation direction of the brake piston

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Brake)

Rear Disc Brake
– The brake cylinder assembly is an assembly
replacement part
Assembly
Replacement Bleeder Plug

Cylinder Boot

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Brake)

Rear Disc Brake
– Parking brake lever travel adjustment

Check and adjust the parking brake lever travel

Confirm the clearance between operation lever and stopper

(at the parking brake released)

Standard:
0 mm

Click!

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- Click the illustration to enlarge view -
Model Outline for Technician Engine Chassis Body Body Electrical

Brake Control System

Speed Sensor
– Speed sensor type has been changed from passive
type to active type
New Model Previous Model
Active Type Passive Type
(Semiconductor) (Magnetic pick-up)

Coil

Magnetic
Rotor MRE

Rotor
Yoke Magnet

Rotor Magnet

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Model Outline for Technician Engine Chassis Body Body Electrical

Brake Control System

Speed Sensor
– MRE internal operation

Constant Voltage Circuit

+B Magnetic
Rotor

2
MRE
Output Output
1 4
2 MRE 4 +
-
3 Comparator 1
Output 0

12V
Output
0V
Comparator

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Model Outline for Technician Engine Chassis Body Body Electrical

Brake Control System

Speed Sensor
– Sensor output

FL+ Power supply (12V)

MRE
FL-

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Model Outline for Technician Engine Chassis Body Body Electrical

Brake Control System

Speed Sensor
– Signal output at extremely low speed rotation can be
ensured

Active Type Passive Type

(Semiconductor) (Magnetic pick-up)

No Detecting
Vehicle

Vehicle
Speed

Speed
Output

Output
Sensor

Sensor

Time Time

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Brake Control System)

Speed Sensor
– Inspection procedure

Skid Control ECU

FL+
12V
FL- to GND

MRE
1.4V
FL-
0.7V
100 
GND
Low Speed High Speed

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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
EPS (Electric Power Steering)
– Column assist type EPS is used

Power Steering ECU

Steering Column Assembly

• Torque Sensor
• DC Brush Motor
• Reduction Mechanism

P/S Warning
Light
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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
System Diagram

Torque Sensor

Reduction
Mechanism

Power Steering
ECU
DC Motor Temp. Sensor
CAN (V Bus) Vehicle
Speed
Signal
ECM Meter ECU
DLC3 • Engine Speed
Signal

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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
Steering Column and Motor
– The reduction mechanism reduces the DC motor
speed and transmits it to the output shaft
Reduction DC Motor
Mechanism
Worm Gear
A
Wheel Gear
(Made of resin)

Torsion Bar Output Shaft

A –A Cross Section

Output
Shaft Torque Column
Sensor Shaft
A

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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
Torque Sensor
– This sensor detects the amount of twist of the torsion
bar

Detection Coil Correction Coil

Torsion
Bar
Input
Output

Detection Ring 3
Detection Ring 2
Detection Ring 1

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Model Outline for Technician Engine Chassis Body Body Electrical

Reference (Steering)
Torque Sensor
– Construction

Detection Coil
Torsion Bar
Correction Coil

Output Input

Detection Detection
Ring 3 Ring 1

Detection
Ring 2

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Model Outline for Technician Engine Chassis Body Body Electrical

Reference (Steering)
Torque Sensor
– Cross section of torque sensor
Detection Coil

Correction Coil

Output

Input

Torsion Bar

Detection Ring 1

Wheel Gear Detection Ring 2

(Reduction
Mechanism) Detection Ring 3
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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
Torque Sensor
– Operation (output) of torque sensor
• VT1 and VT2 are same characteristic

[V] Torque
Detection Coil Correction
(VT1, VT2 Value) Coil

Voltage
Neutral position
Output Input

VT1, VT2
(Detection Coil)

Detection Detection [N·m]

Ring 3 Ring 1 Left Turn Right Turn
Steering torque and
Detection rotation direction
Ring 2

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Steering)

Torque Sensor
– When malfunction occurs in torque sensor, output
difference is appear between VT1 and VT2

[V]
Output
Detection Coil Malfunction difference
(VT1, VT2 Value) will appear

Voltage
VT1 Neutral position
Output Input
VT2

[N·m]
Left Turn Right Turn
Steering torque and
rotation direction

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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
EPS Operation
– There are the following functions in assist control

Item Function

Calculates the assist current from the steering torque value and
Basic Control
the vehicle speed, and actuates the power steering motor

Inertia Compensation Ensures the starting movement of the power steering motor when
Control the driver starts to turn the steering wheel

During the short interval between the time the driver fully turns
Recovery Control 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
Damper Control 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
System Overheat duration. If the temp. of motor or power steering ECU exceeds the
Protection Control standard, it limits the amperage to prevent the motor or ECU from
overheating

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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
Fail-safe
– When the system detects the malfunction, system
enters to fail-safe mode as follows
Problem Fail-safe Operation

• Torque Sensor Malfunction

• Motor Overcurrent
Disables the assist
• Motor Short (Including drive system malfunction)
• Power Steering ECU System Malfunction

• Motor Overheating
• Power Steering ECU High Temperature
• Power Steering ECU Internal Temperature Sensor Limits the assist force
Malfunction
• Vehicle Speed and Engine Speed Signals Malfunction

Pauses the assist

Power Supply Voltage Malfunction (Provides normal assist
after the voltage recovers)

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Model Outline for Technician Engine Chassis Body Body Electrical

Steering
Initialization and Calibration
– Perform the initialization and calibration of EPS system
in the following cases

Torque Sensor
Replace Adjustment
Steering Column Power
Assembly Steering
ECU

Using Intelligent Tester

Steering effort differs

between left and right

Using SST Check Wire

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Model Outline for Technician Engine Chassis Body Body Electrical

Service Point (Steering)

Initialization and Calibration
– Using SST (09083-18040)
Procedure

• DTCs are not outputted except C1515/15

Precondition • Center the steering wheel and align the front tires straight ahead
• Ignition switch OFF

1.Turn the ignition switch ON and wait for 3 sec. or more

Initialization of 2.Connect terminals TS and CG of the DLC3 using SST
1 power steering 3.Connect and disconnect terminal TC and CG 20 times within 20 sec.
ECU 4.Checking the PS warning light illuminates then turn the ignition
switch to OFF after disconnecting SST

1.Connect terminals TS and CG and turn the ignition switch ON

NOTE: Do not touch the steering wheel after the ignition switch ON
Calibration of
2 2.Wait for 7 sec.
torque sensor
3.Checking the PS warning light blinks then turn the ignition switch
OFF after disconnecting SST

NOTE:
• Initialization and calibration cannot be performed when the DTCs are outputted except
C1515/15
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