Transcript YARIS (Chassis) - Selamat Datang di SMK Negeri 3 Buduran

Model Outline
Contents
Engine
Click a Section Tab
1
Chassis
Body
Body Electrical
Model Outline
Engine
Chassis
Manual Transaxle
Automatic Transaxle
Brake
Steering
2
Body
Body Electrical
Model Outline
Chassis
Engine
Manual Transaxle
Body
Body Electrical
C50 Manual Transaxle
– Specification
Type
Gear Ratio
Diff. Gear Ratio
Oil Capacity (liter)
Oil Viscosity
Oil Grade
3
C150 (prev.)
C50 (new)
1st
3.545
←
2nd
1.904
←
3rd
1.310
←
4th
0.969
←
5th
0.815
←
Reverse
3.250
←
3.722
4.058
1.9
75W-90
API GL-4 or 5
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Body Electrical
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
6.8
6.4
ATF T-IV
ATF WS
Fluid Capacity (liter)
Fluid Type
4
*: Counter Gear Ratio is included
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Body Electrical
U340E Automatic Transaxle
– ATF type is changed to WS from T-IV for fuel economy
by reducing its viscosity
ATF Viscosity
Thick
T-IV
WS
ATF Temp.
5
High
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Body Electrical
U340E Automatic Transaxle
– ATF WS is not interchangeable with other type of ATF
(e.g. T-IV)
6
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Body Electrical
U340E Automatic Transaxle
– Color of Level Gauge is change from Orange to Black
7
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Shift Control in uphill/downhill traveling
Body Electrical
– Minimize gear shifting on uphill/downhill driving to ensure
smooth driving
4th  3rd  4th
4th  3rd
Brake!
8
Model Outline
Engine
Automatic Transaxle
Chassis
Shift Control in uphill/downhill traveling
Body
Body Electrical
– 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.
9
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Uphill/Downhill Judgment
Body Electrical
– Uphill: Actual Acceleration < Reference Acceleration
– Downhill: Actual Acceleration > Reference Acceleration
: Reference Acceleration
: Actual Acceleration
Uphill
10
Downhill
Model Outline
Engine
Automatic Transaxle
Chassis
Body
Body Electrical
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)
1.
Turn Ignition switch off
2.
Connect IT II to DLC3
3.
Turn IG On and tester switch on
4.
Perform reset memory procedure from the main menu
5.
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
11
Model Outline
Brake
Engine
Chassis
Rear Disc Brake (G grade)
Body
Body Electrical
– Built-in parking brake is used for rear disc brake model
(same as Yaris)
Built-in
Parking
Brake
12
Model Outline
Brake
Engine
Chassis
Body
Parking Brake Buzzer
Body Electrical
– 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 !
13
Model Outline
Engine
Brake Control System
Chassis
Body
Body Electrical
Mechanical Brake Assist
Without BA during emergency braking
Constant
Pressure
Chamber
With BA during emergency braking
Slide Valve Hook
Slide Valve
Control Valve “Close”
PUSH
Power
Piston
14
Operation
Rod
Air Valve “Wide Open”
Variable Pressure Chamber
Model Outline
Chassis
Engine
Steering
Body
Body Electrical
Electric Power Steering is used
– EPS is used (same as Yaris EPS)
Torque Sensors
Reduction
Mechanism
EPS ECU
DC Motor
Temp. Sensor
CAN
15
DLC3
Meter ECU
DTC
Warning Light
Skid Control
ECU
Engine ECU
(ECM)
Vehicle Speed
Signal
Engine Speed
Signal
Model Outline
Steering
Engine
Parts Locations
16
Chassis
Body
Body Electrical
Model Outline
Steering
Chassis
Engine
Body
Body Electrical
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
Worm Gear
[Motor]
Column
Shaft
Stator
Torque
Sensor
Wheel
Gear
Torsion Bar
Output
Shaft
17
Input Shaft
Wheel Gear
Column Shaft
Model Outline
Steering
Chassis
Engine
Body
Body Electrical
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
Output
Shaft
18
Input Shaft
Wheel Gear
Column Shaft
Model Outline
Steering
Engine
Torque Sensor
– Output voltage
19
Chassis
Body
Body Electrical
Model Outline
Steering
Engine
Chassis
Body
Body Electrical
EPS Operation
– There are the following functions in assist control
Item
Basic Control
Inertia Compensation
Control
20
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
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
Model Outline
Steering
Engine
Chassis
Body
Body Electrical
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
C1514 / 14
Torque sensor power supply abnormal
Illuminate
C1515 / 15
Torque sensor zero point adjustment undone
Illuminate
C1516 / 16
Torque sensor zero point adjustment incomplete
Illuminate
C1517 / 17
Torque hold abnormal
Illuminate
C1524 / 24
Motor circuit malfunction
Illuminate
C1512 / 12
C1513 / 13
21
Model Outline
Steering
Chassis
Engine
Body
Body Electrical
Diagnosis and Fail-safe
DTC No.
C1531 / 31
P/S
ECU malfunction
Illuminate
ECU malfunction
Illuminate
C1551 / 51
IG power source voltage malfunction
Illuminate
C1552 / 52
PIG power supply voltage malfunction
Illuminate
C1554 / 54
Power supply relay failure
Illuminate
C1555 / 55
Motor relay failure
Illuminate
C1581 / 81
Assist map number un-writing
Illuminate
U0073 / 91
Control module communication bus off
Illuminate
U0105 / 92
Lost communication with powertrain ECU
U0121 / 93
Lost communication with anti-lock brake system (ABS)
control module
C1532 / 32
C1533 / 33
C1534 / 34
22
Detection Item

Illuminate
Model Outline
Steering
Engine
Chassis
Body
Body Electrical
Diagnosis and Fail-safe
Fail-safe Operation
Prohibits steering assist control
Until temperature falls
Limits steering
assist control
23
Items
•
•
•
•
Malfunction of torque sensor
Motor short
Motor overcurrent
Malfunction of EPS ECU
• 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
Model Outline
Steering
Engine
Chassis
Body
Body Electrical
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
24
Using the SST
NOTE: These operation cannot be performed when the DTCs are
outputted except C1515 / C1525
Model Outline
Service Point
Engine
Chassis
Body
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
Select
Chassis

EPS

Utility

Torque Sensor
Adjustment
Click!
25
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
26
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
27
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
28
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
29
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
30
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
31
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
10
32
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
10
33
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
34
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
35
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
10
36
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
37
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
(Steering)
Initialization and Calibration
– Using the intelligent tester-II
38
Body
Body Electrical
Model Outline
Service Point
Engine
Chassis
Body
Body Electrical
(Steering)
Initialization and Calibration
– If DTCs are outputted except C1515 / C1525
39
Model Outline
Service Point
Engine
Chassis
Body
Body Electrical
(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
Ts
Tc
3. Check that DTC C1515/15 is
output
HINT: If P/S ECU has been replaced, Initialization is not necessary
40
Model Outline
Service Point
Engine
Chassis
Body
Body Electrical
(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
CG
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
Ts
4. Disconnect the SST
HINT: Do not touch the steering wheel during calibration
41