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

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U660E Automatic Transaxle

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General Compact, lightweight and high-capacity 6-speed Super ECT

U660E
3

U660E Automatic Transaxle


Specification
Model Engine Type Transaxle Type 1st 2nd 3rd Gear Ratio 4th

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New ALPHARD 2GR-FE U660E 3.300 1.900 1.420 1.000

07 CAMRY 2GR-FE U660E

5th
6th Reverse Differential Gear Ratio*1 Fluid Capacity*2 [Liter (US qts, Imp. qts)] Fluid Type
*1: Counter gear ratio included

0.713
0.608 4.148 3.935 6.54 (6.91, 5.76) TOYOTA Genuine ATF WS
*2: Differential included

3.685 6.57 (6.94, 5.78)

U660E Automatic Transaxle


Features
Gear Portion

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2 planetary gear units are used Number of planetary gear unit, clutch and one-way clutch is reduced from U151E

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 Hydraulic Portion 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 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 drives intension Lock-up clutch control & flex lock-up clutch control operation range is increased The curvature of the differential case opening is enlarged to moderate the stress concentration

Control

Other
5

U660E Automatic Transaxle

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General Compact 6-speed transaxle

U660E

U151E

U660E Automatic Transaxle

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Planetary Gear Unit Number of planetary gear unit, clutch and one-way clutch is reduced from U151E
U660E
F1 C2 C1 C0 C2 B2 B3

U151E
B1
B1 F1 B2 C1

C3

: Clutch : Brake : One-way Clutch


7

F2 B3

U660E Automatic Transaxle

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Torque Converter The pump impeller and turbine runner portions have been made narrower
Narrowed

U660E U151E
Transaxle Type Torque Converter Type Stall Torque Ratio U660E 3-Element, 1-Step, 2-Phase 1.78

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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 U151E
B

A Standard: B = A + 1 mm [0.03937 in.] or more

U660E Automatic Transaxle

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Clutch Piston for C2 Split piston that acts in the pull direction
Split Type Piston

Divided Clutch (C2)

Spring

Non-Split Type Piston

10

U660E Automatic Transaxle

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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

Linear Solenoid Valve

Solenoid Modulator Valve Control Valve

Line Pressure

Brake

Brake

Line Pressure
11

U660E Automatic Transaxle

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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

SLU

SL2

SL1

12

U660E Automatic Transaxle

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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

Lower Valve Body

13

U660E Automatic Transaxle

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Oil Strainer A felt made pleated oil strainer is used

Oil Strainer

Oil Pan

14

U660E Automatic Transaxle

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Differential Case The curvature of the differential case opening is enlarged to moderate the stress concentration
: Tensile Stress : Compressive Stress

Large Curvature

Stresses applied to differential case opening during driving

15

U660E Automatic Transaxle

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TCM (Transaxle Control Module) TCM is mounted on the transaxle


TCM

16

U660E Automatic Transaxle

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Automatic Transaxle Compensation Code Automatic transaxle compensation code (60-digit) on the QR label
QR Label

Automatic Transaxle Compensation Code (60-digit)

17

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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 READ A/T CODE O After the replacement SET A/T CODE O*1 O RESET MEMORY (O*2) (O*2) O O

ROAD TEST
O O O O O

TCM Automatic Transaxle Valve Body Assembly Shift Solenoid Valve (SL1 and SL2) Shift Solenoid Valve (SL3 and SL4)

*1: When the transaxle compensation code cannot be read from previous TCM, input the 60digit 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
18

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

19

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

20

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

21

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

22

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

Input

Open

23

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Automatic Transaxle Compensation Code A/T Code Registration (Set Compensation Code)
(15 digits x 4 times) Input
123451234512345

Next

Open

24

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

25

U660E Automatic Transaxle


Control

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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
26

U660E Automatic Transaxle

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Clutch to Clutch Pressure Control This control is operated at 2 3 4 5 6 shift change


ATF Temp. Sensor Input Turbine Speed Sensor Counter Gear Speed Sensor V Bus (Local) Air Flow Meter Water Temp. Sensor Throttle Position Sensor

TCM

ECM

SL1
C1

SL2
C2

SL3
B1

SL4
B3

Line Pressure
27

U660E Automatic Transaxle

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Powertrain Cooperative Control Excellent start-off performance is ensured


[Throttle Control at Launch]
: U660E
: Conventional

Accelerator Pedal Opening

Throttle Valve Opening


Response improved

Tire Slippage Suppression

Engine Output

Time
28

U660E Automatic Transaxle

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Powertrain Cooperative Control The gear position during accelerator pedal OFF is determined by the drives pedal operation
[Deceleration Force Control]
: Sudden accelerator pedal operation
: Slow accelerator pedal operation

Accelerator Pedal Opening


5th 6th

Gear Position

3rd

4th

Engine output is changed by drivers input

Engine Output Time


29

U660E Automatic Transaxle

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Powertrain Cooperative Control Excellent response and shift shock reduction are achieved
[Transient Shifting Control] Drivers desired drive force Accelerator Pedal Operation Drivers desired drive force is achieved

ECM
ETCS-i Control ESA Control

TCM
Drives Solenoid Valve

Optimal engine output

Engine Solenoid Valve (SL1, SL2, SL3, SL4)

Automatic Transaxle

30

U660E Automatic Transaxle

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Lock-up Timing Control & Flex Lock-up Clutch Control Operation range
[Lock-up Timing Control] Gear 1st 2nd 3rd 4th 5th Position or Range D or S6 X S5 X S4 X [Flex Lock-up Clutch Control] Gear 1st 2nd 3rd 4th 5th Position or Range D or S6 X * * S5 X * * S4 X *

6th

6th

: Available X: Not available : Not applicable *: Flex Lock-up also operates, when the vehicle is decelerating

31

U660E Automatic Transaxle

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Coast Downshift Control This control maintains sufficient engine speed and keeps fuel cut control operating for as long as possible
Fuel Cut Control ON
Fuel Cut Control OFF With Control Fuel cut time is expanded Without Control

Engine Speed

6th 5th

to 5th

to 4th

Fuel Cut Control ON

to 4th

to 3rd

Fuel Cut Control OFF Time

32

U660E Automatic Transaxle

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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 -

P R N D 5 S

S4 P

S5

Vehicle Speed

R
N D

+
S

S Position Indicator Light

Shift Pattern
33

U660E Automatic Transaxle

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Multi-Mode Automatic Transmission When holding the shift lever to + position 1 second or more, the shift range is shifted up to S6 range
S1 S4 S5

S2

S6

R N D

6 S

S3
Hold 1 sec. or more

R
N D

+
S

Shift Range
S6 (D) S5 S4 S3

Usable Gear
6th 5th 4th 3rd 1st 1st 1st 1st

Shift Pattern
34

S2
S1

2nd
1st

1st

U660E Automatic Transaxle


Fail-safe
Malfunction Part Input Turbine Speed Sensor Counter Gear Speed Sensor ATF Temp. Sensor TCM Power Supply (Voltage is Low)

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Function Shifting to only either the 1st or 3rd gears is allowed. 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. Shifting between the 1st to 4th gears is allowed. 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 Shifting to only either the 1st or 3rd gears is allowed. Knock Sensor Shifting between the 1st to 4th gears is allowed.

Solenoid Valve SL1, The current to the failed solenoid valve is cut off and control is SL2, SL3 and SL4 effected by operating the other solenoid valves with normal operation

35

U660E Automatic Transaxle


DTCs for TCM
DTC No. P0715

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Detection Item Input/Turbine Speed Sensor Circuit Malfunction

Trouble Area Input Turbine Speed Sensor (Hall IC Type) Counter Gear Speed Sensor (Hall IC Type) ATF Pressure Switch 1 ATF Pressure Switch 2 ATF Pressure Switch 3 Solenoid Valve SL4

P0791
P0872 P0873 P0877 P0878 P0989 P0990 P2808 P2810

Intermediate Shaft Speed Sensor "A" Circuit


Transmission Fluid Pressure Sensor/Switch "C" Circuit Low Transmission Fluid Pressure Sensor/Switch "C" Circuit High Transmission Fluid Pressure Sensor/Switch "D" Circuit Low Transmission Fluid Pressure Sensor/Switch "D" Circuit High Transmission Fluid Pressure Sensor/Switch "E" Circuit Low Transmission Fluid Pressure Sensor/Switch "E" Circuit High Pressure Control Solenoid "G Performance Pressure Control Solenoid "G Electrical

36

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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

NOTE: If there is no ATF leak from transaxle, check of the ATF level is no required

37

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Initial Refill / Replacement Service Procedure


1: Refill the ATF 1. Lift the vehicle

Refill Plug

2.
3.

Remove the refill plug and the overflow plug


Fill up ATF from the refill hole until overflowing from the overflow plug hole

4.
5. 6. 7.

Install the overflow plug


Refill ATF* from the refill hole Install the refill plug Lowering the vehicle Overflow Plug

*: Refer to the 40th slide


38

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Automatic Fluid (ATF) TOYOTA Genuine ATF WS is used for fuel economy by reducing its viscosity
Thick

ATF Viscosity

T-IV
WS

ATF Temp.

High

39

Service Point

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Initial Refill / Replacement Service Procedure Refill Quantity


Service Part Replacement of transaxle New torque converter is used Torque converter is reused Refill Quantity [Liter (US qts, Imp. qts)] 5.3 (5.6, 4.7) 3.4 (3.6, 3.0)

Removal and installation of oil pan Removal and installation of drive shaft Removal and installation of valve body Removal and installation of torque converter Replacement of oil cooler Repair of oil leakage

2.8 (3.0, 2.5)


3.2 (3.4, 2.8) 4.8 (5.1, 4.2) 0.5 (0.5, 0.4)

40

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Fluid Level Check (Without Intelligent Tester) Service Procedure


2: ATF temperature check 1. 2. 3. 4. 5. 6. 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 CG TC

P R N

1.5 secs. or less

+ D S -

D N
6 secs. or more

41

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Fluid Level Check (With Intelligent Tester) Service Procedure


2: ATF temperature check 1. 2. 3. 4. 5. 6. 7. 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.

P R N

1.5 secs. or less

+ D S -

D N
6 secs. or more

42

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Fluid Level Check Service Procedure


3: Adjust the ATF level 1. 2. 3. 4. 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 Overflow Plug

5.
6. 7.

Install the overflow plug and the refill plug


Lower the vehicle Stop the engine

43

Suspension and Axle

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Suspension MacPherson strut type front suspension Torsion beam type rear suspension with toe-correct function

44

Suspension and Axle

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Suspension Specification Wheel alignment


Type Tread Front Wheel Alignment* Caster Camber Toe-in [mm (in.)] [degree] [degree] [mm (in.)] MacPherson Strut 1,580 (62.2) 5 40 -0 10 1 (0.04) 11 25 Torsion Beam

Steering Axis Inclination (Reference) [degree] Type Rear Wheel Alignment*

Tread
Camber Toe-in

[mm (in.)]
[degree] [mm (in.)]

1,585 (62.4)
-1 30 3 (0.12)

*: Unloaded Vehicle Condition

45

Brake

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Specification
Master Cylinder Brake Booster Type Diameter Type Tandem 22.2 mm (0.87 in.) Single

Size
Caliper Type Wheel Cylinder Diameter Rotor Size (D x T) Pad

10.5 in.
AX63 63.5 mm (2.50 in.) 296 mm x 28 mm (11.65 in. x 1.10 in.) PV565H

Front Brake

Caliper Type
Rear Brake Wheel Cylinder Diameter Rotor Size (D x T) Pad Parking Brake Type Drum Inner Diameter

ZOH43
42.86 mm (1.69 in.) 298 mm x 12 mm (11.73 in. x 0.47 in.) NS254 Duo servo 190 mm (7.48 in.) ABS with EBD, BA, TRC, VSC and Cooperative Control with EPS BOSCH With

Brake Control Function Skid Control ECU and Brake Actuator Manufacture VSC OFF Switch
46

Brake

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Brake Booster Single diaphragm type brake booster with a tie rod structure for weight reduction

Tie Rod Structure

47

Brake

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Rear Brake Caliper cylinder made of aluminum

Aluminum

48

Brake Control System

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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

MRE

Rotor

Yoke

Magnet

New ALPHARD

Previous ALPHARD

49

Brake Control System

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Speed Sensor MRE internal operation

Constant Voltage Circuit +B Magnetic Rotor MRE Output 2 4

1 2 MRE 4 3 + -

Output

Comparator 1 Output 0 Output 12V 0V

Comparator

50

Brake Control System


Speed Sensor Sensor output

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FL+

Power supply (12V)

MRE
FL-

51

Brake Control System

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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 Time Sensor Output

Sensor Output

Time

52

Service Point

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Speed Sensor Inspection procedure

Skid Control ECU


FL+ MRE FL100
Low Speed High Speed 1.4V 0.7V

12V

FL- to GND

GND

53

Brake Control System

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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 ECM Main Body ECU Steering Angle Sensor Yaw Rate and Acceleration Sensor

Skid Control ECU

Brake

Brake Actuator

Cooperative Control with EPS


Controls Assist Force Power Steering ECU

54

Brake Control System

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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
Increase Assist Power
[Rear Wheel Skid Tendency]

Increase Assist Power


[Front Wheel Skid Tendency]

Low High

Low High

[Braking Suddenly] [Accelerating Suddenly]


55

Reduce Assist Power

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(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 PKB

Release and apply twice


56

VSC and TRC OFF

Change to an engine switch OFF Inspection mode is canceled

Tire and Wheel

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Tire and Wheel Size and Design


Grade Tire Size Size Material P.C.D.* 350G 215/65R16 16 x 6.5 J 350S 215/60R17 17 x 7.0 J

Aluminum with Center Cap 114.3 mm (4.5 inch)

Off Set
Disc Wheel

33 mm (1.3 inch)

Design

*: Pitch Circle Diameter

57

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(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

Punctured Tire Spare Tire

58

Steering

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EPS (Electric Power Steering) Motor drives the column shaft


Power Steering ECU

P/S Warning Light

[Specification]
Type Gear Ratio (Overall) No. of Turns Lock to Lock Vehicle Speed Sensing Type 16.5 3.30 Steering Column Assembly Brushless Motor with Rotational Angle Sensor Reduction Mechanism Hall IC Type Torque Sensor

Rack Stroke
59

[mm (in.)]

143.8 (5.66)

Steering

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System Diagram
Hall IC Type Torque Sensors Reduction Mechanism

Torque Sensor Signals

Rotation Angle Sensor Signal

Brushless Motor (Resolver Type Rotational Angle Sensor included) V Bus No.1

Power Steering ECU


Temp. Sensor Boost Converter

DLC3

DTC

Air Conditioning Amplifier

Combination Meter P/S Warning Light

Skid Control ECU Vehicle Speed Signal

ECM Engine Speed Signal

60

Steering

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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 Torsion Bar Worm Gear

Stator

Output Shaft

Input Shaft Wheel Gear

Column Shaft

61

Steering

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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
Motor Output Shaft Yoke

[Torque Sensor]
Input Shaft

Multipole Magnet Torque Sensor Torsion Bar Hall ICs

Torsion Bar

Output Shaft

Input Shaft Wheel Gear

Column Shaft

62

Steering

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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]
Input Shaft Magnetic Flux Left Turn (+) Hall IC1 Output Voltage (V) Right Turn

Hall IC2

(-)

Twisted Angle of Torsion Bar (deg) Yoke Output Shaft : Hall IC1 Signal : Hall IC2 Signal : Neutral Position

63

Steering

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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]
Input Shaft

[Turn to Left]
Input Shaft

[Turn to Right]
Input Shaft

Output Shaft

Output Shaft

Output Shaft

64

Steering

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EPS Operation There are the following functions in assist control


Item
Basic Control Inertia Compensation Control Recovery Control

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 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 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 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 Controls EPS system in order to facilitate the driver to operate the steering in a direction that stabilizes the vehicle during VSC operating Limits the operation of the electric load when the battery voltage decreases

Damper Control

System Overheat Protection Control Cooperative Control with EPS EPS Electric Load Control

65

Steering

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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

Limitation Demand

Rear Window Defogger

66

Steering

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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. C1511 / 11 C1512 / 11 C1513 / 11 C1514 / 11 C1515 / 15 C1516 / 16 C1517 / 11 C1521 / 25 C1522 / 25 C1523 / 24 C1524 / 24 C1525 / 17 C1526 / 18
67

Detection Item

Torque sensor malfunction Torque sensor power supply abnormal Torque sensor zero point adjustment undone Torque sensor zero point adjustment incomplete Torque hold abnormal

Illuminate Illuminate Illuminate Illuminate Illuminate

Motor malfunction

Illuminate

Rotation angle sensor output initialization undone Rotation angle sensor output initialization incomplete

Illuminate Illuminate

Steering
DTC No.

Model Outline

for Technician

Engine

Chassis

Body

Body Electrical

Diagnosis and Fail-safe


Detection Item Motor rotation angle sensor malfunction ECU malfunction ECU malfunction Vehicle speed signal malfunction Illuminate Illuminate Illuminate C1528 / 12 C1531 / 25 C1532 / 25 C1533 / 25 C1534 / 25 C1541 / 13

C1551 / 25
C1552 / 22 C1554 / 23 C1555 / 25 C1581 / 26 U0100 / 41 U0129 / 42

IG power source voltage malfunction


PIG power supply voltage malfunction Power supply relay failure Motor relay welding failure Assist map number un-writing Lost communication with ECM Lost communication with brake system control module

Illuminate
Illuminate Illuminate Illuminate Illuminate

68

Steering

Model Outline

for Technician

Engine

Chassis

Body

Body Electrical

Diagnosis and Fail-safe When the system detects the malfunction, system enters to fail-safe mode as follows
Fail-safe Operation Items Torque sensor malfunction Motor overcurrent Motor short (Including drive system malfunction) Power steering ECU malfunction

Disables the assist

Limits the assist force

Motor overheating Power steering ECU internal temperature sensor malfunction Vehicle speed signal malfunction Engine speed signal malfunction Power supply voltage malfunction

Temporary limits the assist*

*: When the normal conditions are reestablished, it returns to normal controls

69

Service Point

Model Outline

for Technician

Engine

Chassis

Body

Body Electrical

(Steering)

Initialization and Calibration Perform the initialization and calibration of EPS system in the following cases using the intelligent tester
Assist Map Writing Power steering ECU replaces Steering column assembly replaces Steering effort differs between turning left and right O Rotation angle Torque sensor zero sensor initialization point calibration O O O O

NOTE: Initialization and calibration cannot be performed when the DTCs (C1516 and C1526) are stored

70

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