Alphard - Chassis Contents Click a Section Tab.

Alphard - Chassis Contents Click a Section Tab

U660E Automatic Transaxle Suspension and Axle Brake
Alphard - Chassis U660E Automatic Transaxle Suspension and Axle Brake Brake Control System Tire and Wheel Steering

U660E Automatic Transaxle
Alphard - Chassis U660E Automatic Transaxle General Compact, lightweight and high-capacity 6-speed Super ECT Basic construction is the same as CAMRY. U660E

Alphard - Chassis U660E Automatic Transaxle Specification Model New ALPHARD ’07 CAMRY Engine Type 2GR-FE Transaxle Type U660E Gear Ratio 1st 3.300  2nd 1.900 3rd 1.420 4th 1.000 5th 0.713 6th 0.608 Reverse 4.148 Differential Gear Ratio*1 3.935 3.685 Fluid Capacity*2 [Liter (US qts, Imp. qts)] 6.54 (6.91, 5.76) 6.57 (6.94, 5.78) Fluid Type TOYOTA Genuine ATF WS *1: Counter gear ratio included *2: Differential included

Alphard - Chassis U660E Automatic Transaxle Features Gear Portion 2 planetary gear units are used Number of planetary gear unit, clutch and one-way clutch is reduced from U151E Hydraulic Portion 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 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 Control 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 drive’s intension Lock-up clutch control & flex lock-up clutch control operation range is increased Other The curvature of the differential case opening is enlarged to moderate the stress concentration

Alphard - Chassis U660E Automatic Transaxle General Compact 6-speed transaxle U660E 6-speed U660E is more compact than 5-speed U151E. U151E

Alphard - Chassis U660E Automatic Transaxle Planetary Gear Unit Number of planetary gear unit, clutch and one-way clutch is reduced from U151E U660E U151E C1 B1 F1 C2 B2 B3 B1 C0 C2 F1 B2 C1 C3 F2 B3 Number of planetary gear unit, clutch and one-way clutch is reduced from U151E. : Brake : Clutch : One-way Clutch

Alphard - Chassis U660E Automatic Transaxle Torque Converter The pump impeller and turbine runner portions have been made narrower Narrowed U660E U151E Transaxle Type U660E Torque Converter Type 3-Element, 1-Step, 2-Phase Stall Torque Ratio 1.78

Service Point (U660E Automatic Transaxle)
Alphard - Chassis Service Point (U660E Automatic Transaxle) Torque Converter Please make sure to check the installation condition of torque converter after you install After the torque converter installation Difficult to install Make sure to check the installation condition Narrowed U660E Please make sure to check the installation condition of torque converter after you install. The torque converter is more difficult to install, because the spline portion of torque converter is made narrower from U151E. U151E B A Standard: B = A + 1 mm [ in.] or more

Alphard - Chassis U660E Automatic Transaxle Clutch Piston for C2 Split piston that acts in the pull direction Split Type Piston Divided Clutch (C2) Spring Split piston (for Clutch C2) that acts in the pull direction. When the split piston operates, clutch drag occurs due to rattling cause by the divided portion of the piston. However, by fitting springs on the piston circumference, such rattling is restrained and the occurrence of clutch drag is minimized. Non-Split Type Piston

Alphard - Chassis U660E Automatic Transaxle 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 Solenoid Modulator Valve Linear Solenoid Valve Control Valve Line Pressure SL1, SL2, SL3 and SL4 solenoid valves control engagement elements by directly regulating the line pressure without using the pressure regulation valve (control valve) or the pressure reduction valve (solenoid modulator valve). The number of valves and the length of the valve body fluid passage have been reduced, the shifting response has been increased and the shift shock has been minimized. Brake Brake Line Pressure

Alphard - Chassis U660E Automatic Transaxle ATF Pressure Switch 3 ATF pressure switches are located in the output fluid passages of SL1, SL2 and SLU Lower Valve Body ATF Pressure Switch 3 ATF Pressure Switch 2 ATF Pressure Switch 1 3 ATF pressure switches detect solenoid valve output fluid pressure of SL1, SL2 and SLU. The TCM detects malfunctions in solenoid valves SL1, SL2, SL3 and SL4 in accordance with the ON/OFF signals from ATF pressure switches 1 and 2, and determines the appropriate fail-safe operation. The ATF pressure switch 3 is used to detect malfunctions in solenoid valves SLU and SL. SLU SL2 SL1

Alphard - Chassis U660E Automatic Transaxle Speed Sensor (NT & NC) Hall IC type speed sensor is used Counter Gear Speed Sensor (Hall IC Type) Input Turbine Speed Sensor (Hall IC Type) Upper Valve Body Hall IC type speed sensor is used for input turbine speed sensor and counter gear speed sensor. Lower Valve Body

Oil Strainer A felt made pleated oil strainer is used Oil Strainer Oil Pan

Alphard - Chassis U660E Automatic Transaxle Differential Case The curvature of the differential case opening is enlarged to moderate the stress concentration : Tensile Stress : Compressive Stress Large Curvature The curvature of the differential case opening is enlarged to moderate the stress concentration. As a result, the differential gear tolerant torque is enhanced, and use of the lightweight 2-pinion differential gears is possible. Stresses applied to differential case opening during driving

Alphard - Chassis U660E Automatic Transaxle TCM (Transaxle Control Module) TCM is mounted on the transaxle TCM TCM is mounted on the transaxle. CAN communication is provided between the TCM and ECM.

Alphard - Chassis U660E Automatic Transaxle Automatic Transaxle Compensation Code Automatic transaxle compensation code (60-digit) on the QR label QR Label Automatic transaxle compensation code (60-digit) on the QR label contains encoded automatic transaxle property information (fluid pressure characteristics compensation values). It improves the initial quality of the shift change after the TCM or transaxle replacement. Automatic Transaxle Compensation Code (60-digit)

Alphard - Chassis Service Point (U660E Automatic Transaxle) 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 After the replacement READ A/T CODE SET A/T CODE RESET MEMORY ROAD TEST TCM O O*1 (O*2) Automatic Transaxle - Valve Body Assembly Shift Solenoid Valve (SL1 and SL2) (SL3 and SL4) [READ A/T CODE] Read the 60-digit compensation code in the TCM and save it to the intelligent tester. [SET A/T CODE] Input the 60-digit compensation code to the TCM. [RESET MEMORY] Reset the compensation values learned by driving (60-digit compensation code is not reset). [ROAD TEST] Check the shift shock, and allow TCM to learn to improve the shift shock. *1: When the transaxle compensation code cannot be read from previous TCM, input the 60-digit 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

Alphard - Chassis Service Point (U660E Automatic Transaxle) Automatic Transaxle Compensation Code A/T Code Registration (Read Compensation Code) [A/T Code Registration (Read Compensation Code)] Read the 60-digit compensation code in the TCM and save it to the Intelligent Tester.

Automatic Transaxle Compensation Code A/T Code Registration (Read Compensation Code)

Alphard - Chassis Service Point (U660E Automatic Transaxle) Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code) [A/T Code Registration (Set Compensation Code)] Input the 60-digit compensation code to the TCM.

Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code) Input Open

Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code) (15 digits x 4 times) Input Next Open

Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code)

Control 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 Coast Downshift Control AI (Artificial Intelligence)-SHIFT Multi-Mode Automatic Transmission

Alphard - Chassis U660E Automatic Transaxle Clutch to Clutch Pressure Control This control is operated at 2  3  4  5  6 shift change ATF Temp. Sensor TCM V Bus (Local) ECM Air Flow Meter Input Turbine Speed Sensor Water Temp. Sensor Counter Gear Speed Sensor Throttle Position Sensor SL1 SL2 SL3 SL4 C1 C2 B1 B3 Clutch to clutch pressure control is used for shift control in the 2nd gear or above. As a result, shift control in the 2nd gear or above is possible without using the one-way clutch. Line Pressure

Alphard - Chassis U660E Automatic Transaxle Powertrain Cooperative Control Excellent start-off performance is ensured [Throttle Control at Launch] : U660E : Conventional Accelerator Pedal Opening Throttle Valve Opening Tire Slippage Suppression By controlling the engine output with ETCS-i when the vehicle starts off, excellent start-off performance (improved response and suppression of tire slippage) is ensured. Response improved Engine Output Time

Alphard - Chassis U660E Automatic Transaxle Powertrain Cooperative Control The gear position during accelerator pedal OFF is determined by the drive’s pedal operation [Deceleration Force Control] : Sudden accelerator pedal operation : Slow accelerator pedal operation Accelerator Pedal Opening 6th 5th Gear Position 4th 3rd The TCM determines the gear position when the accelerator pedal is OFF in accordance with the operation of the accelerator pedal (released suddenly or slowly) during deceleration. It realizes the deceleration which responded to the drive’s intension. Preventing unnecessary upshifts and downshifts when the accelerator pedal is OFF and ensuring smooth acceleration when the vehicle needs to accelerate again. Engine output is changed by driver’s input Engine Output Time

Alphard - Chassis U660E Automatic Transaxle Powertrain Cooperative Control Excellent response and shift shock reduction are achieved [Transient Shifting Control] ECM TCM Driver’s desired drive force ETCS-i Control ESA Control Drives Solenoid Valve Accelerator Pedal Operation Driver’s desired drive force is achieved Optimal engine output Engine In this control, performs integrated control of the ETCS-i and ESA and A/T clutch engagement fluid pressure Solenoid Valve (SL1, SL2, SL3, SL4) Automatic Transaxle

Alphard - Chassis U660E Automatic Transaxle Lock-up Timing Control & Flex Lock-up Clutch Control Operation range [Lock-up Timing Control] [Flex Lock-up Clutch Control] Gear Position or Range D or S6 S5 S4 1st X 2nd  3rd 4th 5th  6th Gear Position or Range D or S6 S5 S4 1st X 2nd  3rd 4th * 5th  6th Operation range of lock-up timing control & flex lock-up clutch control are increased. By allowing flex lock-up timing control to continue operating during gearshift, the smooth torque transmission is obtained. : Available X: Not available : Not applicable *: Flex Lock-up also operates, when the vehicle is decelerating

Alphard - Chassis U660E Automatic Transaxle Coast Downshift Control This control maintains sufficient engine speed and keeps fuel cut control operating for as long as possible With Control Fuel Cut Control ON Fuel cut time is expanded Without Control Fuel Cut Control OFF to 5th to 4th Fuel Cut Control ON 6th Engine Speed 5th Fuel economy is achieved. Fuel Cut Control OFF to 4th to 3rd Time

Alphard - Chassis U660E Automatic Transaxle 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 - S 5 P R N D S4 S5 R N D S + - P Vehicle Speed S Position Indicator Light Shift Pattern

Alphard - Chassis U660E Automatic Transaxle Multi-Mode Automatic Transmission When holding the shift lever to “+” position 1 second or more, the shift range is shifted up to S6 range S 6 P R N D S1 S2 S3 S4 S5 S6 R N D S + - P Hold 1 sec. or more Shift Range Usable Gear S6 (D) 6th st S5 5th st S4 4th st S3 3rd st S2 2nd st S1 1st Shift Pattern

Fail-safe Malfunction Part Function Input Turbine Speed Sensor Shifting to only either the 1st or 3rd gears is allowed. Counter Gear 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. ATF Temp. Sensor TCM Power Supply (Voltage is Low) 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 Knock Sensor Solenoid Valve SL1, SL2, SL3 and SL4 The current to the failed solenoid valve is cut off and control is effected by operating the other solenoid valves with normal operation

Alphard - Chassis U660E Automatic Transaxle DTCs for TCM DTC No. Detection Item Trouble Area P0715 Input/Turbine Speed Sensor Circuit Malfunction Input Turbine Speed Sensor (Hall IC Type) P0791 Intermediate Shaft Speed Sensor "A" Circuit Counter Gear Speed Sensor (Hall IC Type) P0872 Transmission Fluid Pressure Sensor/Switch "C" Circuit Low ATF Pressure Switch 1 P0873 Transmission Fluid Pressure Sensor/Switch "C" Circuit High P0877 Transmission Fluid Pressure Sensor/Switch "D" Circuit Low ATF Pressure Switch 2 P0878 Transmission Fluid Pressure Sensor/Switch "D" Circuit High P0989 Transmission Fluid Pressure Sensor/Switch "E" Circuit Low ATF Pressure Switch 3 P0990 Transmission Fluid Pressure Sensor/Switch "E" Circuit High P2808 Pressure Control Solenoid "G“ Performance Solenoid Valve SL4 P2810 Pressure Control Solenoid "G“ Electrical New DTCs are added from U151E automatic transaxle.

Alphard - Chassis Service Point (U660E Automatic Transaxle) 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 [Inspection procedure] 1. Visually check the fluid leak. 2. If there is ATF leak from transaxle, adjust the ATF level. Note: If there is no ATF leak from transaxle, adjustment of the ATF level is no required. Notice: ***Removing of the overflow plug without engine running will flow out fluid. Follow the procedures for fluid refill and fluid level check to prevent accidental loss of fluid. NOTE: If there is no ATF leak from transaxle, check of the ATF level is no required

Alphard - Chassis Service Point (U660E Automatic Transaxle) Initial Refill / Replacement Service Procedure 1: Refill the ATF Refill Plug Lift the vehicle Remove the refill plug and the overflow plug Fill up ATF from the refill hole until overflowing from the overflow plug hole Install the overflow plug Refill ATF* from the refill hole Install the refill plug Lowering the vehicle [Refill the ATF] 1. Lift the vehicle 2. Remove the refill plug and the overflow plug 3. Fill up ATF from the refill hole until overflowing from the overflow plughole 4. Install and tighten the overflow plug 5. Refill ATF from the refill hole (The amount of the refilled ATF is different depending on the content of work) Note: If you cannot add the listed amount of fluid, do the following. (a) Install the refill plug (b) Allow the engine to idle with the A/C OFF (c) Move the shift lever through entire gear range to circulate fluid (d) Wait for 30 seconds with the engine idling (e) Stop the engine (f) Remove the refill plug and add fluid (g) Reinstall the refill plug 6. Install the refill plug 7. Lower the vehicle Overflow Plug *: Refer to the 40th slide

Alphard - Chassis Service Point (U660E 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 type WS (Lower viscosity at normal operating temperature range) [Maintenance Schedule] Normal: Inspect every 40,000 km (24 months). Severe: Inspect every 40,000 km (24 months). Replace every 80,000 km (48 months). ATF Temp. High

Initial Refill / Replacement Service Procedure Refill Quantity Service Part Refill Quantity [Liter (US qts, Imp. qts)] Replacement of transaxle New torque converter is used 5.3 (5.6, 4.7) Torque converter is reused 3.4 (3.6, 3.0) Removal and installation of oil pan Removal and installation of drive shaft 2.8 (3.0, 2.5) Removal and installation of valve body 3.2 (3.4, 2.8) Removal and installation of torque converter 4.8 (5.1, 4.2) Replacement of oil cooler Repair of oil leakage 0.5 (0.5, 0.4)

Alphard - Chassis Service Point (U660E Automatic Transaxle) Fluid Level Check (Without Intelligent Tester) Service Procedure 2: ATF temperature check CG TC Using the SST, connect TC and CG of DLC3 Start the engine Shift into position from P to D range Move the shift lever quickly between N and D position Confirm “D” position indicator lights up for 2 sec. Shift to P and remove the SST DLC3 1.5 secs. or less + - P R D N S D [ATF temperature check] (Without Intelligent Tester) Using the SST (SST No ), connect the terminals TC - CG of DLC3 Start the engine Shift into position from P to D range, and return to P range at engine idling and brake depressing Move the shift lever back and forth between N and D at an interval of 1.5 seconds for 6 seconds or more Confirm “D” position indicator lights up for 2 seconds (Shift to test mode) Return the shift lever to P range position and disconnect the SST from terminals TC and CG of the DLC3 N 6 secs. or more

Alphard - Chassis Service Point (U660E Automatic Transaxle) Fluid Level Check (With Intelligent Tester) Service Procedure 2: ATF temperature check Connect the Intelligent Tester to DLC3 Turn the engine on and turn the Intelligent Tester on Check A/T oil temperature Start the engine Shift into position from P to D range Move the shift lever quickly between N and D position Confirm “D” position indicator lights up for 2 sec. 1.5 secs. or less + - P R D N S D [ATF temperature check] (With Intelligent Tester) Connect the Intelligent Tester Turn the engine switch on and turn the Intelligent Tester on Enter the following menu: Power train / Engine / Active Test / Connect the TC and TE1 Select the Data List menu: A/T Oil Temp from ECT Check A/T oil temperature Note: If ATF temp. is 45 °C [113 °F] or more, turn the engine switch off and wait until ATF temp. drops below 45 °C [113 °F]. Select the Active Test menu: Connect the TC and TE1 / ON Start the engine Shift into position from P to D range, and return to P range at engine idling and brake depressing Move the shift lever quickly between N and D range position until “D” position indicator lights up Confirm “D” position indicator lights up for 2 seconds (Shift to test mode) Return the shift lever to P range position Select the Active Test menu: Connect the TC and TE1 / OFF N 6 secs. or more

Alphard - Chassis Service Point (U660E Automatic Transaxle) Fluid Level Check Service Procedure 3: Adjust the ATF level Engine idling warm-up ATF Verify “D” position indicator turns on (ATF temp. check) Lift up the vehicle with engine idling Check the ATF level by ATF overflow from overflow plug hole Install the overflow plug and the refill plug Lower the vehicle Stop the engine Overflow Plug [Adjustment the ATF level] 1. Raise the temperature of ATF by idling 2. When “D” position indicator comes on, lift the vehicle with engine running Note: “D” position indicator will indicate the ATF temperature as follows. - Under proper ATF temperature: Turn off - Proper ATF temperature (40 to 45 °C [104 to 113 °F]): Turn on - More than proper ATF temperature: Blinking 3. Lift the vehicle 4. Remove the overflow plug If ATF will overflows from the overflow plug, tighten the overflow plug If no ATF overflow, add ATF into the refill hole until ATF flows from the overflow plug 5. Install the overflow plug and tighten to the specified torque: Standard 40 N·m (408 kgf·cm, 30 ft·lbf) 6. Install the refill plug and tighten to the specified torque: Standard 49 N·m (500 kgf·cm, 36 ft·lbf) 7. Lower the vehicle 8. Stop the engine

Suspension and Axle Suspension MacPherson strut type front suspension
Alphard - Chassis Suspension and Axle Suspension MacPherson strut type front suspension Torsion beam type rear suspension with toe-correct function Toe-correct function is equipped the previous ALPHAED.

Suspension and Axle Suspension Specification Wheel alignment
Front Wheel Alignment* Type MacPherson Strut Tread [mm (in.)] 1,580 (62.2) Caster [degree] 5° 40’ Camber [degree] -0° 10’ Toe-in [mm (in.)] 1 (0.04) Steering Axis Inclination (Reference) [degree] 11° 25’ Rear Wheel Alignment* Torsion Beam 1,585 (62.4) -1° 30’ 3 (0.12) *: Unloaded Vehicle Condition

Brake Specification Master Cylinder Type Tandem Diameter
Alphard - Chassis Brake Specification Master Cylinder Type Tandem Diameter 22.2 mm (0.87 in.) Brake Booster Single Size 10.5 in. Front Brake Caliper Type AX63 Wheel Cylinder Diameter 63.5 mm (2.50 in.) Rotor Size (D x T) 296 mm x 28 mm (11.65 in. x 1.10 in.) Pad PV565H Rear Brake ZOH43 42.86 mm (1.69 in.) 298 mm x 12 mm (11.73 in. x 0.47 in.) NS254 Parking Brake Duo servo Drum Inner Diameter 190 mm (7.48 in.) Brake Control Function ABS with EBD, BA, TRC, VSC and Cooperative Control with EPS Skid Control ECU and Brake Actuator Manufacture BOSCH VSC OFF Switch With VSC OFF switch is added. - TRC OFF: Push a VSC OFF switch - VSC and TRC OFF: Push and hold a VSC OFF switch

Alphard - Chassis Brake Brake Booster Single diaphragm type brake booster with a tie rod structure for weight reduction The tie rod structure improves the strength of the brake booster. Therefore the thickness of the brake booster body can be thinned for weight reduction. Tie Rod Structure

Brake Rear Brake Caliper cylinder made of aluminum Aluminum
Alphard - Chassis Brake Rear Brake Caliper cylinder made of aluminum Aluminum Rear brake caliper cylinder is made of aluminum.

Active Type (Semiconductor) Passive Type (Magnetic pick-up)
Alphard - Chassis Brake Control System 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 Rotor MRE Speed sensor type has been changed from passive type to active type. Signal output at extremely low speed rotation can be ensured. (Detection speed = Approx. 0 km/h) This speed sensor cannot detect the rotation direction of the wheel. MRE: Magnetic Resistance Element Yoke Magnet New ALPHARD Previous ALPHARD

Constant Voltage Circuit
Alphard - Chassis Brake Control System Speed Sensor MRE internal operation Constant Voltage Circuit +B Magnetic Rotor 2 MRE Output Output 1 4 2 MRE 4 + - Comparator Output 1 3 The MRE resistance changes depending on the direction of the magnetic force applied to the MRE. When the direction of the magnetic force changes according to the rotation of the magnetic rotor, the MRE output becomes an AC waveform. The comparator in the sensor converts this AC waveform into a digital signal and outputs it. [Magnetic Rotor Type] The waveform frequency is determined by the number of poles of the magnetic rotor. This sensor uses 48-pole type magnetic rotor. It generates a 48 pulses for each rotation of the magnetic rotor. 12V Output 0V Comparator

Brake Control System Speed Sensor Sensor output MRE FL+ FL-
Alphard - Chassis Brake Control System Speed Sensor Sensor output FL+ Power supply (12V) MRE FL- The signal from MRE is send to the sensor IC, which is powered by battery voltage. Based on the order of receiving the MRE signal, the sensor IC outputs a voltage onto the “-” line of the speed sensor.

Active Type (Semiconductor) Passive Type (Magnetic pick-up)
Alphard - Chassis Brake Control System 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 Sensor Output Sensor Output Time Time

Service Point (Brake Control System)
Alphard - Chassis Service Point (Brake Control System) Speed Sensor Inspection procedure Skid Control ECU FL+ 12V FL- to GND MRE 1.4V FL- 0.7V To inspect the sensor operation, the sensor needs to receive battery voltage to operate 1. Turn on the engine switch. 2. Don’t disconnect any connector. 3. Measure between the “-” line and GND on the ECU wire harness side the output voltage while rotating the wheel in both directions. The scope screen should indicate the signal as indicated. 100  GND Low Speed High Speed

Cooperative Control with EPS
Alphard - Chassis Brake Control System 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 Brake Actuator Skid Control ECU ECM Main Body ECU Brake Cooperative Control with EPS Steering Angle Sensor Controls Assist Force Power Steering ECU Yaw Rate and Acceleration Sensor

Brake Control System Cooperative Control with EPS
Alphard - Chassis Brake Control System 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 [Rear Wheel Skid Tendency] Low  High  Low  High  Increase Assist Power Increase Assist Power [Front Wheel Skid Tendency] Increase assist power for facilitating the driver’s steering maneuvers in direction to correct. Reduce assist power for preventing the driver’s excessive turning of the steering wheel. Reduce Assist Power [Braking Suddenly] [Accelerating Suddenly]

Service Point (Brake Control System)
Alphard - Chassis Service Point (Brake Control System) 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 TRC and VSC systems can be turned off by transfer to the inspection mode. [Transfer to the inspection mode] Note: It can also transfer to the inspection mode by using the intelligent tester Vehicle Conditions: Engine switch OFF / P Range / Parking Brake ON Perform the following procedure within 30 sec. 1. Start engine 2. Depress the brake pedal twice 3. Release and apply the parking brake pedal twice while depressing the brake pedal 4. Depress the brake pedal twice with parking brake applied 5. Check that the slip indicator light is turned on Note: The brake control system will return to the normal mode by turning the engine switch off PKB VSC and TRC OFF Release and apply twice Change to an engine switch OFF  Inspection mode is canceled

Tire and Wheel Tire and Wheel Size and Design Grade 350G 350S
Alphard - Chassis Tire and Wheel Tire and Wheel Size and Design Grade 350G 350S Tire Size 215/65R16 215/60R17 Disc Wheel Size 16 x 6.5 J 17 x 7.0 J Material Aluminum with Center Cap P.C.D.* 114.3 mm (4.5 inch) Off Set 33 mm (1.3 inch) Design <Tire Inflation Pressure> Front - For driving under 160 km/h (99 mph): 240 kPa (2.4 kgf/cm2, 35 psi) - For driving at 160 km/h (99 mph) or over: 300 kPa (3.1 kgf/cm2, 44 psi) Rear *: Pitch Circle Diameter

Service Point (Tire and Wheel)
Alphard - Chassis Service Point (Tire and Wheel) Spare Tire Spare tire carrier cannot accommodate ground tire Wrap punctured tire in wrapping sheet, and store it in luggage compartment Wrapping Sheet Wrap The wrapping sheet is stored in the tool bag. Punctured Tire Spare Tire

Vehicle Speed Sensing Type
Alphard - Chassis Steering EPS (Electric Power Steering) Motor drives the column shaft Power Steering ECU P/S Warning Light [Specification] The basic structure and operation is the same as PREVIA. Type Vehicle Speed Sensing Type Gear Ratio (Overall) 16.5 No. of Turns Lock to Lock 3.30 Rack Stroke [mm (in.)] 143.8 (5.66) Steering Column Assembly Brushless Motor with Rotational Angle Sensor Reduction Mechanism Hall IC Type Torque Sensor

Steering System Diagram Power Steering ECU DTC
Alphard - Chassis Steering System Diagram Hall IC Type Torque Sensors Torque Sensor Signals Reduction Mechanism Rotation Angle Sensor Signal Power Steering ECU Brushless Motor (Resolver Type Rotational Angle Sensor included) Temp. Sensor Boost Converter V Bus No.1 Temperature sensor and boost converter are provided in the power steering ECU. - Temp. sensor to detect the temperature of the power steering ECU, if the sensor detects the overheating, the assist current to the motor is reduced in order to lower the temp. - Boost converter converts the voltage of the battery and supplies the power source to the motor. Power steering ECU uses the CAN protocol for diagnosis communication. Air Conditioning Amplifier Combination Meter Skid Control ECU ECM DLC3 DTC Vehicle Speed Signal Engine Speed Signal P/S Warning Light

Steering Steering Column and Brushless Motor
Alphard - Chassis Steering 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 Column Shaft Torque Sensor Worm Gear Stator Brushless Motor Low inertia, low nose, and high power output motor is driven by an ordinary voltage of 33V - Boost converter in power steering ECU converts the voltage of the battery from 12V to 33V (max. 40V) and supplies the power source to the motor Wheel gear is made of a high strength, low friction, and low wear resin material Worm gear supported by ball bearings Torsion Bar Input Shaft Output Shaft Column Shaft Wheel Gear

Steering 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 [Torque Sensor] Output Shaft Motor Input Shaft Yoke Multipole Magnet Torsion Bar Torque Sensor Hall ICs Torsion Bar Input Shaft Output Shaft Column Shaft Wheel Gear

[When steering turned to Right]
Alphard - Chassis Steering 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] Magnetic Flux Input Shaft Left Turn (+) Right Turn Hall IC1 Output Voltage (V) Hall IC2 Two Hall ICs One is used for controlling the motor, other one is used for detecting of malfunction (fail-safe) by comparison with Hall IC1 signal Hall IC2 is receiving the magnetic flux of the same direction as the Hall IC1, but it outputs the signal of the opposite direction, because it is installing in the direction opposite to the Hall IC1 (-) Twisted Angle of Torsion Bar (deg) Yoke : Hall IC1 Signal : Hall IC2 Signal Output Shaft : Neutral Position

Steering Torque Sensor (detection of twisted angle of torsion bar)
Alphard - Chassis Steering 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] [Turn to Left] [Turn to Right] Input Shaft Input Shaft Input Shaft In driven straight (not twisted the torsion bar), the yoke is located between each pole limit Magnetic Pole: 24 poles Each pole: 12 poles A pole: 15 degree Torsion Bar Twist angle: Plus or minus 2.11 degree from center Output Shaft Output Shaft Output Shaft

Steering EPS Operation
Alphard - Chassis 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 Cooperative Control with EPS Controls EPS system in order to facilitate the driver to operate the steering in a direction that stabilizes the vehicle during VSC operating EPS Electric Load Control Limits the operation of the electric load when the battery voltage decreases

Steering 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 Power Steering ECU V Bus No.1 Loading Control Level Signal OFF Air Conditioning Amplifier Rear Window Defogger Limitation Demand

Steering Diagnosis and Fail-safe
Alphard - Chassis Steering 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. Detection Item C1511 / 11 Torque sensor malfunction Illuminate C1512 / 11 C1513 / 11 C1514 / 11 Torque sensor power supply abnormal C1515 / 15 Torque sensor zero point adjustment undone C1516 / 16 Torque sensor zero point adjustment incomplete C1517 / 11 Torque hold abnormal C1521 / 25 Motor malfunction C1522 / 25 C1523 / 24 C1524 / 24 C1525 / 17 Rotation angle sensor output initialization undone C1526 / 18 Rotation angle sensor output initialization incomplete [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

Steering Diagnosis and Fail-safe DTC No. Detection Item C1528 / 12
Alphard - Chassis Steering Diagnosis and Fail-safe DTC No. Detection Item C1528 / 12 Motor rotation angle sensor malfunction Illuminate C1531 / 25 ECU malfunction C1532 / 25 C1533 / 25  C1534 / 25 C1541 / 13 Vehicle speed signal malfunction C1551 / 25 IG power source voltage malfunction C1552 / 22 PIG power supply voltage malfunction C1554 / 23 Power supply relay failure C1555 / 25 Motor relay welding failure C1581 / 26 Assist map number un-writing U0100 / 41 Lost communication with ECM U0129 / 42 Lost communication with brake system 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)

Limits the assist force
Alphard - Chassis Steering Diagnosis and Fail-safe When the system detects the malfunction, system enters to fail-safe mode as follows Fail-safe Operation Items Disables the assist Torque sensor malfunction Motor overcurrent Motor short (Including drive system malfunction) Power steering ECU malfunction Limits the assist force Motor overheating Power steering ECU internal temperature sensor malfunction Temporary limits the assist* Vehicle speed signal malfunction Engine speed signal malfunction Power supply voltage malfunction *: When the normal conditions are reestablished, it returns to normal controls

Service Point (Steering)
Alphard - Chassis Service Point (Steering) Initialization and Calibration Perform the initialization and calibration of EPS system in the following cases using the intelligent tester Assist Map Writing Rotation angle sensor initialization Torque sensor zero point calibration Power steering ECU replaces O Steering column assembly replaces - Steering effort differs between turning left and right [Assist map writing] Connect the intelligent tester to DLC3 Turn the engine switch on and the intelligent tester on Enter the following menu: Chassis/EMPS/Assist Map Wait for 5 sec. or more Check for DTCs [Rotation angle sensor initialization and torque sensor zero point calibration] Precondition Enter the following menu: Chassis/EMPS/Data List Check the value of the following item: IG Power Supply Standard Value: 10 to 14 V Rotation angle sensor initialization and torque sensor zero point calibration Enter the following menu: Chassis/EMPS/Utility/Torque Sensor Adjustment NOTE: Initialization and calibration cannot be performed when the DTCs (C1516 and C1526) are stored

Alphard - Chassis Contents Click a Section Tab.

Similar presentations

Presentation on theme: "Alphard - Chassis Contents Click a Section Tab."— Presentation transcript:

Similar presentations

About project

Feedback

Log in

Auth with social network:

Alphard - Chassis Contents Click a Section Tab.

Similar presentations

Presentation on theme: "Alphard - Chassis Contents Click a Section Tab."— Presentation transcript:

Similar presentations

About project

Feedback