Chassis Automatic Transmission Brake Control System Steering VGRS (Variable Gear Ratio Steering) System Tire and Wheel

Chassis Automatic Transmission A750F Automatic Transmission –A750F 5-speed automatic transmission (Super ECT ) is newly added -A-W-Q-V

Chassis Automatic Transmission A750F Automatic Transmission –Fuel economy and dynamic performance have been improved : [Wide Gear Ratio] A343F A750F Total Gear Ratio (Differential Included) Acceleration Performance Fuel Economy 1st2nd3rd4th 5th : st : : (14)(3) -A-W-Q-V

Chassis Automatic Transmission Specification Model 03 LX47002 LX470 Transmission Type A750FA343F Gear Ratio 1st nd rd th th Reverse Fluid Capacity [Liters (US qts, Lmp. qts)] 10.8 (11.4, 9.5)12.0 (12.7, 10.6) Fluid Type ATF Type T-IVATF Type D-II or equivalent -A-W-Q-V

Chassis Automatic Transmission A750F Automatic Transmission –Gate type shift lever is newly used [Shift Indicator Light] -A-W-Q-V

Chassis Automatic Transmission Oil Pump –The crescent has been discontinued. As a result oil pump has made more compact and the driving torque has been reduced Drive Gear Driven Gear Pump Body: Made of aluminum to reduce the weight Stator Shaft Assembly Crescent discontinued -A-W-Q-V

Chassis Automatic Transmission Planetary Gear Unit –The 5-speed configuration has been achieved without increasing the number of planetary gear : Brake : Clutch : One-way Clutch [A750] [A650] Input Output 3 Planetary Gears -A-W-Q-V

Chassis Automatic Transmission Various Control –A750F are performing the following controls Centrifugal Fluid Pressure canceling Line Pressure Optimal Control Clutch Pressure Control Flex Lock-up Clutch Control AI (Artificial Intelligence) -shift Control -A-W-Q-V

Chassis Brake System Specification –Front caliper type has been changed for –A and – W models -A-W-Q-V Destination-A, -W-Q, -V Master Cylinder TypeSingle (Double Piston) Diameter [mm (in.)]26.99 (1.06) Brake Booster TypeHydraulic Front Brake TypeVentilated Disc Caliper TypeS15+13S14+12 Wheel Cylinder Dia. [mm (in.)] (Front cylinder + Rear cylinder) 51.1 x x 2 (2.01 x x 2) 48.1 x x 2 (1.89 x x 2) Rotor Size (D x T) [mm (in.)]313 x 32 (12.32 x 1.26) Rear Brake TypeVentilated Disc Wheel Cylinder Dia. [mm (in.)]48.1 (1.89) Rotor Size (D x T) [mm (in.)]329.4 x 18 (12.97 x 0.71)

Chassis Brake Control System ABS with EBD, Brake Assist, A-TRAC & VSC System –The deceleration sensor and solenoid valves are changed Yaw Rate Sensor Deceleration Sensor Switching and Control Solenoid Valves Combination Meter Skid Control ECU Warning Light Signal Hydraulic Brake Booster Various Sensors -A-W-Q-V

Chassis Brake Control System Yaw Rate and Deceleration Sensor –Deceleration sensor has been integrated in the yaw rate sensor Deceleration Sensor (G Sensor) Yaw Rate Sensor -A-W-Q-V

Chassis Brake Control System Switching and Control Solenoid Valves –The resistance value of the coil of the solenoid valve was changed for continuation operation time extension of the system Solenoid Valve Regulator cut solenoid Pressure holding solenoid (4-wheels) Accumulator cut solenoid Master cylinder cut solenoid (FL/FR) Continuation Operation Time 03 LX470 Approx. 7.2 Approx minutes 02 LX470 Approx. 5.0 Approx seconds NOTE When the voltage is 13 V: New Model: 7.2 x 7.2 x 1.81 A = W Previous Model: 5 x 5 x 2.60 A = 33.8 W -A-W-Q-V

Chassis Steering Overall –Internal-external tube bushings and low friction rack guide have been adopted to facilitate a natural steering feeling Internal-external Tube Bushing Low-friction Rack Guide -A-W-Q-V

Chassis Steering Reverse Variable Gear Ratio Type Rack Bar –Gear ratio near the end position of the rack bar is shorter than near the neutral steering position -A-W-Q-V Neutral Position End Position Hollow Type Steering Rack Bar Steering Stroke Ratio

Chassis Steering Specification Item03 LX470 (w/ VGRS)02 LX470 Gear Ration (Overall)12.4 – 18.0*19.8 No. of Turns Lock to Lock *3.8 Fluid TypeATF Type DEXRON ® II of III *: The gear ratio and the number of lock-to-lock turns are made variable for the VGRS system -A-W-Q-V

Chassis VGRS (Variable Gear Ratio Steering) System General –The steering gear ratio will be changed in accordance with the vehicle speed Low Ratio (Quick) High Ratio (Slow) Vehicle speed lowVehicle speed high a a a + -A-W-Q-V

Chassis VGRS System System Diagram (Main Signal) VGRS ECU VGRS Actuator Skid Control ECU VGRS Warning Light Suspension Control ECU Steering Angle Sensor DLC3 Steering Angle Steering Wheel Neutral Position Vehicle Speed Engine Speed Etc. VGRS Actuator Operating Angle Engine Speed Wheel Angle (Steering Angle + VGRS Actuator Operating Angle) Control Signal Temp. Sensor Rotational Angle Sensor Lock Mechanism Engine ECU (ECM) VGRS Actuator Actual Operating Angle -A-W-Q-V

Chassis VGRS System Location VGRS ECU VGRS Actuator Steering Angle Sensor VGRS Warning Light Combination Meter -A-W-Q-V

Chassis VGRS System Steering Gear Ratio Vehicle Speed Steering Gear Ratio : 03 Model with VGRS System : 02 Model Comparison of the gear ratio Gear Ratio : 12.4 Lock to Lock : 2.4 Gear Ratio : 18.0 Lock to Lock : 3.5 Slow Gear Ratio : 17.3 Lock to Lock : 3.3 Quick Gear Ratio : 19.8 Lock to Lock : 3.8 VGRS system not operates -A-W-Q-V

Chassis VGRS System Normal Operation VGRS Actuator VGRS ECU Steering Angle Sensor Vehicle Speed Skid Control ECU Steering Angle Vehicle Speed Actuator Operating Angle Map Calculate actuator target operating angle Control Signal (Target Operating Angle) Motor Gear -A-W-Q-V

Reference VGRS System Control –The VGRS ECU adds the supplemental assist with steering speed to reduce delay of vehicle response VGRS + Assist Actuator Output Normal Operation -A-W-Q-V

Slippery Surface Chassis VGRS System Cooperative Control of Brake Control System –For example, in order to enable quicker steering when braking suddenly (VSC active) Drives steering effort Braking Effectiveness of Cooperative Control of Brake Control System -A-W-Q-V

Reference VGRS System Cooperative Control of Brake Control System –This control operates by signal from skid control ECU VGRS ECU VGRS Actuator Skid Control ECU Request the cooperative control Most low gear ratio assist -A-W-Q-V

Chassis VGRS System VGRS Actuator Reduction Mechanism Lock Mechanism DC Motor Spiral Cable VGRS Actuator Steering Wheel Rack & Pinion Rubber Coupling -A-W-Q-V

Service Point VGRS System VGRS Actuator –Exchange VGRS actuator assembly (overhaul is impossible) Remove Assembly New VGRS Actuator Install Assembly Broken VGRS Actuator Parts Number: A-W-Q-V

Chassis VGRS System Spiral Cable –Flexible flat cable is used VGRS ECU Power Source Control Signal Rotational angle and rotational direction of the DC motor Motor -A-W-Q-V

Service Point VGRS System Spiral Cable –Secure the neutral position of this cable before installing VGRS actuator (same as spiral cable for drivers airbag) 1. Turn the cable clockwise until it becomes harder to turn 2. Then turn the cable counterclockwise about 2.5 turns 2.5 rev. -A-W-Q-V

Reference VGRS System Spiral Cable –System diagram (VGRS ECU VGRS actuator) VGRS Actuator Lock Solenoid MV MSU VGRS ECU MSV MSW MG BMU BMV BMW LG DC Brush– less Motor Spiral Cable Hall ICs -A-W-Q-V

Chassis VGRS System Lock Mechanism –This mechanism locks the motor shaft, so that if the system will be failure Motor Shaft AA A – A Cross Section Lock Holder (Motor Shaft) Solenoid Lock Lever (Housing) Return Spring -A-W-Q-V

Chassis VGRS System Lock Mechanism Solenoid ONSolenoid OFF System is Normal Engine is stopped System is failure (Fail Safe) LockUnlock -A-W-Q-V

Chassis VGRS System Motor –A compact high-output low-noise DC brush-less motor is controlled by duty signal Magnet Coil Motor Shaft Rotational Angle sensor (Three Hole ICs) is included in the motor DC Motor Reduction Mechanism -A-W-Q-V

Driven Gear Stator Gear Flexible Gear Wave Generator Chassis VGRS System Reduction Mechanism –The strain wave gearing type reduction mechanism is used Steering Wheel Motor Output Shaft Stator Gear Wave Generator Driven Gear Flexible Gear -A-W-Q-V

Chassis VGRS System Reduction Mechanism –Components Steering WheelRack & Pinion Wave Generator (input) Stator Gear (input) Driven Gear (output) Flexible Gear -A-W-Q-V

Chassis VGRS System Reduction Mechanism –Components Coupled to the housing of the VGRS actuator Flexible metal body Gear teeth are meshed with the inside of both stator gear and driven gear Coupled to the output shaft of the VGRS actuator Consists an oval- shaped cam and bearing Rotated by the DC motor Number of teeth: 102Number of teeth: The difference of number of teeth Wave Generator (input) Stator Gear (input) Driven Gear (output) Flexible Gear Teeth -A-W-Q-V

Chassis VGRS System Reduction Mechanism –Construction View from stator gear side (Steering wheel side) Meshing Not meshing Ball Bearing is between flexible gear and wave generator Stator Gear Wave Generator Flexible Gear -A-W-Q-V

Chassis VGRS System Reduction Mechanism –Operation of strain wave gearing The flexible gear is flexed into an oval shape by wave generator The teeth of flexible gear meshes with the teeth of stator gear and driven gear The wave generator rotates View from stator gear side (stator gear fixed) The meshed area of the flexible gear and stator gear and driven gear moves in sequence The flexible gear moves by 2 teeth because the flexible gear has 2 fewer teeth than the stator gear The driven gear moves by 2 teeth (=Actuator output) The wave generator makes one turn The driven gear and flexible gear have the same number of teeth, so their rotational movements are identical -A-W-Q-V

Reference VGRS System Reduction Mechanism View from stator gear side -A-W-Q-V Stator Gear Wave Generator Flexible Gear Motor Shaft Ball Bearing (Between flexible gear and wave generator)

Click Picture Chassis VGRS System Reduction Mechanism –Operation of strain wave gearing The wave generator makes one turn Every time motor rotates, flexible gear and stator gear shifts by two teeth Moves 2 teeth The shift is used as actuator output 102 teeth 100 teeth -A-W-Q-V

Gear Ratio Motor Flexible Gear Chassis VGRS System Reduction Mechanism –Gear ratio Wave generator (motor) rotates 50 times Flexible gear rotates one time : teeth 100 teeth -A-W-Q-V

Chassis VGRS System Operation (Turn the left when vehicle speed is low) –The motor rotates the clockwise and adds steering angle Click Picture Steering wheel 1 rev. -A-W-Q-V

Reference VGRS System Components -A-W-Q-V Motor Flexible Gear Steering Wheel Output Stator Gear Driven Gear Actuator Housing Wave Generator

Chassis VGRS System Operation (Turn the left when vehicle speed is mid.) –The motor does not operate and no assist Motor 0 rev. / Steering wheel 1 rev. Click Picture -A-W-Q-V

Chassis VGRS System Operation (Turn the left when vehicle speed is high) –The motor rotates the counterclockwise and reduces steering angle Steering wheel 1 rev. Click Picture -A-W-Q-V

Chassis VGRS System VGRS Warning Light –VGRS warning light comes ON when the system is malfunction -A-W-Q-V

Chassis VGRS System VGRS ECU (Fail-safe 1) Malfunction PartsFail-safe Operation VGRS Warning Light DTC Memory Condition Steering Angle Sensor Malfunction System stop (Lock mechanism) DC Motor Malfunction VGRS ECU Malfunction DC Motor Circuit Malfunction Lock Mechanism Circuit Malfunction Vehicle Speed Signal Malfunction Skid Control ECU Communication Signal Malfunction -A-W-Q-V

Chassis VGRS System VGRS ECU (Fail-safe 2) Malfunction PartsFail-safe Operation VGRS Warning Light DTC Memory Condition DC Motor Overheat (approx. 100C * 1 ) First, the control is stopped; then, the control resume after the system resumes its normal operation VGRS ECU Overheat (approx. 100C) PIG Power Source Drop Voltage Malfunction VGRS Actuator Malfunction * 2 * 1 : The temperature presumed from the motor drive current * 2 : Specific examples 1)When the steering operated while the output of the power steering pump is unstable, immediately after starting a cold engine 2)If the driver attempts to operate the steering wheel further after is has been steered entirely to the rock end -A-W-Q-V

Chassis VGRS System Diagnosis –DTCs 1/3 DTCsDetection item C1511 / 11Steering Angle Sensor Malfunction C1515 / 15 VGRS Actuator Neutral Position undone C1516 / 16 C1521 / 21 VGRS Actuator Malfunction C1522 / 22 C1527 / 27 C1528 / 28 C1531 / 31 VGRS ECU Malfunction C1532 / 32 C1533 / 33 -A-W-Q-V

Chassis VGRS System Diagnosis –DTCs 2/3 DTCsDetection item C1541 / 41Skid Control System Malfunction C1549 / 49Skid Control System Communication Malfunction C1551 / 51IG Power Source Voltage Malfunction C1552 / 52DC Motor Power Source Voltage Malfunction C1554 / 54Power Source Relay failure C1555 / 55Predriver Source Relay Failure -A-W-Q-V

Chassis VGRS System Diagnosis –DTCs 3/3 DTCsDetection item C1561 / 61Lock Mechanism Malfunction C1567 / 67Lock Mechanism Insertion Malfunction C1568 / 68Lock Holder Deviation Detection C1569 / 69Lock Mechanism Release Incomplete Test Mode C1571Vehicle Speed Sensor Malfunction (FLO) C1572Vehicle Speed Sensor Malfunction (FRO) C1575Steering Angle Sensor Malfunction C1576DC Motor Revolution Angle Sensor Malfunction -A-W-Q-V

Chassis VGRS System Initialize –Initialize VGRS ECU, after exchange VGRS ECU or VGRS actuator Install Remove Initialize VGRS ECU Install Remove When the VGRS ECU initialize is undone, the DTC (C1515 or C1516) is memorized -A-W-Q-V

Service Point VGRS System Initialize –Initialize VGRS ECU, after exchange VGRS ECU or VGRS actuator IG OFF Exchange VGRS ECU or VGRS actuator IG ON (Tire:going-straight direction) Next page VGRS ECU initializing start Without hand- held tester -A-W-Q-V

IG OFF VGRS ECU Initializing is finished Steering wheel is neutral position Steering wheel neutral positioning Yes No Check the DTC There is C1515 Initialize VGRS ECU Yes No (VGRS warning light lights up) C1515: The state which can initialize the VGRS ECU Click! -A-W-Q-V

IG ON Next page Short and open the terminals TC and CG of the DLC3 10 times or more within 20 sec. Initialize VGRS ECU Engine starts Move the steering wheel to the neutral position Connect terminals TS and CG of the DLC3 (Vehicle speed: 0km/h) Without hand- held tester Turn the steering wheel to left side more than 180º -A-W-Q-V

Turn the steering wheel to neutral position Short and open the terminals TC and CG of the DLC3 10 times or more within 20 sec. (VGRS warning light lights up) Check the VGRS warning light is lighting Open terminals TS and CG of the DLC3 IG OFF Return to VGRS ECU initializing start -A-W-Q-V

Supply 12V between MV and LG terminal of the connector (actuator side) (Lock mechanism is unlocked) Disconnect negative (-) terminal cable from the battery Turn the steering wheel to neutral position Steering wheel neutral positioning Without hand- held tester IG OFF Disconnect the VGRS actuator connector Cut 12V between MV and LG terminal of the connector (actuator side) (Lock mechanism is locked) Within 3 min. Next page -A-W-Q-V

Connect the VGRS actuator connector VGRS ECU initializing is finished Connect negative (-) terminal cable from the battery Turn the steering wheel 3º to left and right (if the steering wheel has anti-power, it is the normal state?) -A-W-Q-V

Chassis Tire and Wheel Tire and Wheel Size –Tire and wheel size have been changed -A-W-Q-V Model-A-W, -Q, -V02 LX470 Size275/60R 18 8JJ275/65R 17 8JJ275/70R16 8JJ Wheel Material Aluminum