1. Instructors Click a Section Tab
Contents
Click a Section Tab
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2. Manual Transaxle
Automatic Transaxle
Brake
Steering

3. 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
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4. 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

5. 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
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6. Automatic Transaxle U340E Automatic Transaxle
ATF WS is not interchangeable with other type of ATF (e.g. T-IV)

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

8. 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!

9. 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.

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

11. 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

12. 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
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13. 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 !

14. 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
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15. 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
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16. Steering
Parts Locations

17. 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
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18. 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

19. Steering
Torque Sensor
Output voltage

20. 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
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21. 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
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22. 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)
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23. 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
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24. 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

25. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
Select
Chassis 
EPS
Utility
Torque Sensor Adjustment
Click!
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26. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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27. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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28. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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29. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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30. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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31. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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32. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II 10
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33. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II 10
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34. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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35. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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36. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II 10
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37. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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38. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the intelligent tester-II
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39. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
If DTCs are outputted except C1515 / C1525
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40. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the SST ( )
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
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41. Service Point (Steering)
Instructors
Service Point (Steering)
Initialization and Calibration
Using the SST ( )
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 seconds
4. Disconnect the SST CG Ts
HINT: Do not touch the steering wheel during calibration
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