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Manual Transaxle Automatic Transaxle Brake Steering

Manual Transaxle C50 Manual Transaxle Specification Type C150 (prev.) Instructors Manual Transaxle C50 Manual Transaxle Specification Type C150 (prev.) C50 (new) Gear Ratio 1st 3.545 ← 2nd 1.904 3rd 1.310 4th 0.969 5th 0.815 Reverse 3.250 Diff. Gear Ratio 3.722 4.058 Oil Capacity (liter) 1.9 Oil Viscosity 75W-90 Oil Grade API GL-4 or 5 Select cable with cable length adjustment mechanism is used to adjust the shift lever neutral position Construction of adjustment mechanism of TMC model and TMMF model is different Vios New Model - Chassis

Automatic Transaxle U340E Automatic Transaxle Specification Type U340E (prev.) U340E (new) Gear Ratio 1st 2.847 ← 2nd 1.552 3rd 1.000 4th 0.700 Reverse 2.343 Diff. Gear Ratio 3.850 4.237* Counter Gear Ratio 1.019 n.a Fluid Capacity (liter) 6.8 6.4 Fluid Type ATF T-IV ATF WS *: Counter Gear Ratio is included

Automatic Transaxle U340E Automatic Transaxle Instructors Automatic Transaxle U340E Automatic Transaxle ATF type is changed to WS from T-IV for fuel economy by reducing its viscosity Thick ATF Viscosity T-IV [For –A, -K and –Q] ATF WS is used for U340E WS ATF Temp. High Vios New Model - Chassis

Automatic Transaxle U340E Automatic Transaxle ATF WS is not interchangeable with other type of ATF (e.g. T-IV)

Automatic Transaxle U340E Automatic Transaxle Color of Level Gauge is change from Orange to Black

Automatic Transaxle 4th  3rd  4th 4th  3rd Shift Control in uphill/downhill traveling Minimize gear shifting on uphill/downhill driving to ensure smooth driving 4th  3rd  4th 4th  3rd Brake!

Automatic Transaxle Shift Control in uphill/downhill traveling When ECU detects uphill travel, it prohibits upshifting to 4th gear after downshifting to 3rd gear If brake signal is detected while ECU detects downhill travel, it downshifts from 4th to 3rd.

Automatic Transaxle Uphill/Downhill Judgment Uphill: Actual Acceleration < Reference Acceleration Downhill: Actual Acceleration > Reference Acceleration : Reference Acceleration : Actual Acceleration Uphill Downhill

Automatic Transaxle Service Points, Initialization Perform RESET MEMORY (AT Initialization) when replacing A/T Assembly, engine assembly or ECM RESET MEMORY can only be performed using Intelligent Tester (cannot completed by disconnecting battery terminal) Turn Ignition switch off Connect IT II to DLC3 Turn IG On and tester switch on Perform reset memory procedure from the main menu Select following items: Powertrain/Engine and ECT/Utility CAUTION: After performing RESET MEMORY, be sure to perform ROAD TEST HINT: ECM stores learned values by performing the ROAD TEST

Built-in Parking Brake Instructors Brake Rear Disc Brake (G grade) Built-in parking brake is used for rear disc brake model (same as Yaris) Built-in Parking Brake [For –W as option / For –T, -D and -E RS grade as standard] Built-in parking brake is used for rear disc bake model Vios New Model - Chassis

BUZER ! Brake Parking Brake Buzzer Buzzer sounds when parking brake is not completely released at vehicle speed of 5 km/h or more. Not properly released 5 km/h or more BUZER !

Constant Pressure Chamber Variable Pressure Chamber Instructors Brake Control System Mechanical Brake Assist Without BA during emergency braking With BA during emergency braking Slide Valve Hook Slide Valve Control Valve “Close” Constant Pressure Chamber PUSH Mechanical brake assist is a standard equipment for –W, -Q, -V, -_(RHD), -T, -D and -E Operation Rod Power Piston Air Valve “Wide Open” Variable Pressure Chamber Vios New Model - Chassis

Steering Electric Power Steering is used Instructors Steering Electric Power Steering is used EPS is used (same as Yaris EPS) Torque Sensors Reduction Mechanism EPS ECU DC Motor Temp. Sensor Temperature sensor and boost converter are provided in the EPS ECU - Temp. sensor to detect the temperature of the EPS ECU, if the sensor detects the overheating, the assist current to the motor is reduced in order to lower the temp. -EPS ECU uses the CAN protocol for diagnosis communication CAN Meter ECU Skid Control ECU Engine ECU (ECM) DLC3 DTC Warning Light Vehicle Speed Signal Engine Speed Signal Vios New Model - Chassis

Steering Parts Locations

Steering Steering Column and DC Motor Instructors Steering Steering Column and DC Motor DC motor with reduction mechanism which reduces motor speed via worm gear and transmits it to the column shaft [Motor] Rotor Motor Worm Gear Column Shaft Stator Torque Sensor Wheel Gear Worm gear supported by ball bearings Torsion Bar Input Shaft Output Shaft Column Shaft Wheel Gear Vios New Model - Chassis

Steering Torque Sensor Torque sensor using detection ring 1 and 2 mounted on the input shaft, and detection ring 3 mounted on the output shaft [Torque Sensor] Motor Torque Sensor Torsion Bar Input Shaft Output Shaft Column Shaft Wheel Gear

Steering Torque Sensor Output voltage

Steering EPS Operation Instructors Steering EPS Operation There are the following functions in assist control Item Function Basic Control Calculates the assist current from the steering torque value and the vehicle speed, and actuates the motor Inertia Compensation Control Improves the starting movement of the motor when the driver starts to turn the steering wheel Recovery Control 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 Damper Control 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 System Overheat Protection Control 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 Vios New Model - Chassis

Steering Diagnosis and Fail-safe Instructors Steering Diagnosis and Fail-safe When malfunction occurs in EPS system, EPS ECU controls following control; Turns on P/S warning light and fail-safe operation DTC No. Detection Item P/S C1511 / 11 Torque sensor malfunction Illuminate C1512 / 12 C1513 / 13 C1514 / 14 Torque sensor power supply abnormal C1515 / 15 Torque sensor zero point adjustment undone C1516 / 16 Torque sensor zero point adjustment incomplete C1517 / 17 Torque hold abnormal C1524 / 24 Motor circuit malfunction [Torque Sensor Malfunction] C1511: Torque sensor (TRQ1) signal error or stop C1512: Torque sensor (TRQ2) signal error or stop C1513: Deviation between torque sensor TRQ1 and TRQ2 is out of specification [Motor Malfunction] C1521: Motor overcurrent C1522: Motor current sensor malfunction C1523: Excessively large current deviation C1524: Voltage error between motor terminals Vios New Model - Chassis

Steering Diagnosis and Fail-safe DTC No. Detection Item P/S C1531 / 31 Instructors Steering Diagnosis and Fail-safe DTC No. Detection Item P/S C1531 / 31 ECU malfunction Illuminate C1532 / 32 C1533 / 33 C1534 / 34 C1551 / 51 IG power source voltage malfunction C1552 / 52 PIG power supply voltage malfunction C1554 / 54 Power supply relay failure C1555 / 55 Motor relay failure C1581 / 81 Assist map number un-writing U0073 / 91 Control module communication bus off U0105 / 92 Lost communication with powertrain ECU  U0121 / 93 Lost communication with anti-lock brake system (ABS) control module [EPS malfunction] C1531: ECU internal malfunction (CPU malfunction) C1532: ECU internal malfunction (Peripheral circuit malfunction) C1533: ECU internal malfunction (Substrate temp. sensor malfunction) C1534: ECU internal malfunction (EEPROM error) Vios New Model - Chassis

Steering Diagnosis and Fail-safe Fail-safe Operation Items Instructors Steering Diagnosis and Fail-safe Fail-safe Operation Items Prohibits steering assist control Malfunction of torque sensor Motor short Motor overcurrent Malfunction of EPS ECU Limits steering assist control Until temperature falls Motor Overheating ECU overheating Until normal signals are received Malfunction of vehicle speed signal Malfunction of engine speed signal Until normal condition Malfunction of power supply voltage Vios New Model - Chassis

Remove, install or replacing Instructors Steering Initialization and Calibration Perform the initialization and calibration of EPS system in the following cases Remove, install or replacing Using Intelligent Tester-II Steering Wheel Steering column assy Steering gear assy Different steering effort (right & Left) EPS ECU Replace the new one Using the SST NOTE: These operation cannot be performed when the DTCs are outputted except C1515 / C1525 Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Select Chassis  EPS Utility Torque Sensor Adjustment Click! Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II 10 Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II 10 Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II 10 Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the intelligent tester-II Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration If DTCs are outputted except C1515 / C1525 Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the SST (09083-18040) 1. Initialization of torque sensor zero point calibration signals 1. Center Steering Wheel and align the front wheel ahead. Connect terminals Tc,Ts and CG and turn the ignition switch to ON 2. Disconnect and connect terminal Tc 20 times or more within 20sec. CG 3. Check that DTC C1515/15 is output Ts Tc HINT: If P/S ECU has been replaced, Initialization is not necessary Vios New Model - Chassis

Service Point (Steering) Instructors Service Point (Steering) Initialization and Calibration Using the SST (09083-18040) 2. Calibration of torque sensor zero point 1. Connect terminals Ts and CG and turn the ignition switch to ON 2. Wait for 7 seconds after P/S warning light comes on. 3. Confirm the P/S warning light blinks at interval of 0.125 seconds 4. Disconnect the SST CG Ts HINT: Do not touch the steering wheel during calibration Vios New Model - Chassis