Contents

1. Contents • Click a Section Tab

2. P410 Hybrid Transaxle • Electric Shift Lever System • Suspension • Brake • Brake Control System • Steering

3. P410 Hybrid Transaxle • Overall • P410 hybrid transaxle mainly consists of the following components Compound Gear Unit • Power Split Planetary Gear (Right Side) • Motor Speed Reduction Planetary Gear (Left Side) MG2 Oil Pump (Mechanical Type) Transaxle Damper MG1 Final Drive Gear Final Driven Gear Counter Driven Gear Differential Gear Unit

4. P410 Hybrid Transaxle • Specification Compound Gear Unit *1: The figure shown is the weight with the oil fully filled.

5. P410 Hybrid Transaxle • Gear Train Power Split Planetary Gear Compound Gear Unit Motor Speed Reduction Planetary Gear Engine Oil Pump Transaxle Damper MG2 MG1 Counter Driven Gear Differential Gear Unit Final Drive Gear

6. P410 Hybrid Transaxle • Gear Train Motor Speed Reduction Device • Sun Gear: MG2 • Planetary Carrier: Fixed • Rear Gear: Compound Gear (to Wheels) Power Split Device • Sun Gear: MG1 • Planetary Carrier: Engine • Ring Gear: Compound Gear (to Wheels) MG2 MG1 Engine To Front Wheel

7. P410 Hybrid Transaxle • Compound Gear Unit • Each planetary ring gear is integrated with the compound gear unit. • Furthermore, this compound gear unit is integrated with a counter drive gear and parking gear. Counter Drive Gear Parking Lock Gear Ring Gear (Motor Speed Reduction Planetary Gear) Ring Gear (Power Split Planetary Gear) Motor Speed Reduction Planetary Gear Unit Power Split Planetary Gear Unit Counter Drive Gear (Compound Gear) [Compound Gear Unit]

8. Transaxle Damper P410 Hybrid Transaxle • Transaxle Damper • Two types of damping characteristics are adopted • Low torsion-type coil spring damper • Dry single-plate friction material prevents the damage to the transaxle by the excessive engine torque by slipping

9. P410 Hybrid Transaxle • Lubrication System • Final gear with an oil sling type lubrication mechanism • Oil catch tank is used in order to supply oil to each gear train from there in a stable manner. Oil Catch Tank Oil Catch Tank Oil Hole MG Motor Cooling Final Gear

10. Front Service Point (P410 Hybrid Transaxle) • Lubrication System • Drain plug and filler plug for hybrid transaxle fluid Filler Plug for Hybrid Transaxle Fluid (10 mm Hexagon) Drain Plug for Hybrid Transaxle Fluid(10 mm Hexagon) Drain Plug for Hybrid System Coolant(10 mm Hexagon)

11. Service Point (P410 Hybrid Transaxle) • Lubrication System • Add hybrid transaxle fluid • Filling method is the same as the conventional manual transaxle 0 to 10 mm (0.394 in.) Filler Plug for Hybrid Transaxle Fluid

12. P410 Hybrid Transaxle • Cooling System • Cooling system that is independent from the engine cooling system is provided to cool the inverter with converter assembly, MG1 and MG2 Inverter with Converter Assembly HV Radiator Reserve Tank HV Radiator (for Inverter) Inverter with Converter Assembly HV Radiator Reserve Tank HV Water Pump with Motor HV Radiator HV Transaxle HV Water Pump with Motor

13. Electric Shift Lever System • Feature • This system changes the shift range using a shift-by-wire technology • Compact shift lever is used. It’s a momentary shift type that returns to the home position when the driver’s hand is released [Shift Position Indicator] P Position Switch Operation signal Only connected electrically Shift Lever Parking Lock Actuator

14. DLC3 Electric Shift Lever System • System Diagram Shift Lever Assembly Transmission Control ECU Parking Lock Actuator Relay Parking Lock Actuator P Position Switch Rotation Angle Sensor Parking Lock Motor P Position Indicator Light V Bus No.1 Certification ECU LIN Immobiliser Code ECU Power Management Control ECU (HV CPU) Combination Meter Shift Lever Position Sensor Shift Position Indicator Shift Sensor Master Warning Light Select Sensor Buzzer Multi-information Display

15. Electric Shift Lever System • Parts Location Multi-information Display Master Warning Light Shift Position Indicator Select Sensor Power Management Control ECU (HV CPU) Shift Sensor Transmission Control ECU Certification ECU Selector Lever Assembly Immobiliser Code ECU • P Position Switch • P Position Indicator Light Parking Lock Actuator

16. Electric Shift Lever System • Shift Lever and Shift Position Indicator • Shift lever is designed to always return to its home position. Therefore, shift position that is current selected can be checked on the shift position indicator Current Shift Position Indication Operated by driver P Position R Position N Position Returns automatically D Position B Position NOTE: When the shift lever is in a position other than D or B, the B position indicator will turn off. Shift Position Indicator

17. Electric Shift Lever System • Shift Control • Table below shows how the shift lever / P position switch operation are controlled at each shift position : Current Position : Positions to which shift position can be changed : with brake pedal depressing : with stopped vehicle : Available always

18. Electric Shift Lever System • Reject Function • To ensure safety, this system might not change the shift position even if the driver operates the shift lever of P position switch in the following cases

19. Electric Shift Lever System • Shift Lever • Shift lever has built-in shift lever position sensor to detect the shift position (R, N, D and B) • Shift lever position sensor consists of a select sensor and shift sensor, and uses Hall ICs for position detection Select Sensor Shift Sensor

20. Output Characteristics 5 Output Voltage [V] 0 Center, B R, N, D Electric Shift Lever System • Shift Lever • Select sensor • Detects the lateral movement of the shift lever • Sensor hall IC contains 2 circuits, one for main signal, one the sub signal (differing characteristics) Hall ICs Magnet Slider (Connected to shift lever)

21. Hall ICs Magnets Cross-section Electric Shift Lever System • Shift Lever • Shift sensor • Detects the longitudinal movement of the shift lever • Sensor hall IC contains 2 circuits, one for main signal, one the sub signal Output Characteristics 5 Output Voltage [V] 0 LHD Model D, B Side R Side RHD Model R Side D, B Side

22. Electric Shift Lever System • P Position Switch • P position indicator light shows the conditions of the electric shift lever system as follows Parking switch

23. Electric Shift Lever System • Parking Lock Control • Upon receiving an actuation signal from the P position switch via transmission control ECU, the motor rotates to engage or disengage the parking lock mechanism Compound Gear • Parking Lock Gear Parking Lock Mechanism Parking Lock Actuator

24. Electric Shift Lever System • Parking Lock Control • Parking lock actuator (SR motor) • Parking lock actuator mainly consists of a switched reluctance motor and a cycloid reduction mechanism • Rotation angle sensor consists of 2 Hall ICs Reduction Mechanism Shift Control Motor W Phase Magnet V Phase Coil U Phase Rotation Angle Sensor (Hall IC) Output Shaft Stator Rotor [Switched Reluctance Motor]

25. : Electric current flows U W V U U W V W V W V W W V V U U U U U U W V W W V V V W U V V W W U U Reference (Electric Shift Lever System) • Parking Lock Control • Parking lock actuator (SR motor) • Electric current is passed through the stator coil. The coil becomes electromagnet, and attracts the rotor (rotor rotates) Electromagnet Magnetism

26. Electric Shift Lever System • Parking Lock Control • Parking lock actuator (Cycloid reduction mechanism) • Cycloid reduction mechanism ensures complete releasing operation for parking lock when vehicle is parked on slope road in which requires a high torque Reduction Mechanism Shift Control Motor Inside Gear (61 teeth) Outside Gear (60 teeth) Eccentric Plate Center Magnet Motor Input Shaft Center Eccentric Plate Rotation Angle Sensor (Hall IC) Output Shaft Output Shaft [Image of Cycloid Reduction Mechanism] * Operation same as VGRS reduction gear

27. [Lock Condition] Electric Shift Lever System • Parking Lock Control • Parking lock mechanism • The engagement of the parking lock pawl with the parking gear that is integrated with the compound gear locks the movement of the vehicle [Unlock Condition] • Parking lock actuator rotes • Parking lock lever is rotated and the parking lock rod is pushed • Parking lock pawl is pushed up • Parking lock pawl engages with the parking gear Parking Gear Engage Portion Parking Lock Lever Parking Lock Pawl Parking Lock Actuator Parking Lock Rod

28. Electric Shift Lever System • DTC • When the malfunction occurs in this system, the transmission control ECU stores the DTCs in its memory *: Remove the “P COM MAIN” fuse (Fuse Box 7.5 A) to erase the these DTCs because the they cannot be erased with the tester

29. Electric Shift Lever System • DTC • Location of “P COM MAIN” fuse • Remove the “P COM MAIN” fuse for approx. 60 sec. to erase the some DTCs “P COM MAIN” Fuse (7.5 A)

30. Electric Shift Lever System • Case of Emergency • To stop the hybrid system • If it cannot shift position into P, the power source mode can be turned off by applying the parking brake If malfunction in parking lock actuator, it cannot shift position into P Power Source Mode OFF is impossible Parking Brake is applied Vehicle Stopped Power Source Mode OFF is possible READY

31. Suspension • Front Suspension • MacPherson strut type independent suspension Shock Absorber • Multi-leaf Type Liner Control Valve Stabilizer Bar [Front Wheel Alignment (Unloaded vehicle)]

32. Suspension • Rear Suspension • Torsion-beam type suspension Shock Absorber • Multi-leaf Type Liner Control Valve Axle Beam Trailing Arm [Rear Wheel Alignment (Unloaded vehicle)]

33. Brake • Specification

34. Brake • Rear Brake • Build-in type disc brake that has a build-in parking brake mechanism is provided Rear Brake Caliper Check Ball Input Shaft PKB OFF PKB ON Crank Lever Disc Pad Push Rod Nut Sleeve Parking Brake Cable Disc Rotor

35. Service Point (Brake) • Rear Brake • Parking brake lever travel adjustment Check and adjust the parking brake lever travel Confirm the clearance between operation lever and stopper (at the parking brake released) Stopper 0.5 mm or less Operation Lever

36. Brake • Emergency Brake Signal • Feature • This function blinks the stop light at sudden braking to reduce the risk of rear-end collision Blinks automatically Suddenly Braking

37. Brake • Emergency Brake Signal • System Diagram V Bus No.1 Yaw Rate and Acceleration Sensor Skid Control ECU Stop Light Control Relay Stop Light Speed Sensors Stop Light Switch Hazard Warning Light Switch Hazard Warning Light

38. Brake • Emergency Brake Signal • Operation Condition Operation Cancel Conditions • Driver release the brake pedal • Vehicle deceleration became less than specified value • Driver pushes the hazard warning light switch Operation Start Conditions • SPD is more than 55 km/h (34 mph) • Driver depresses the brake pedal • Vehicle deceleration exceeded specified value

39. Brake Control System • ECB (Electronically Controlled Brake) System • A new ECB system changed the following items from the current ECB system to realize a compact and lightweight • The master cylinder, skid control ECU, sensors, solenoid valves and stroke simulator are integrated • The hydraulic brake booster is used as a mechanism back-up if the brake system fails ECU Solenoid Valves Sensors Stroke Simulator Hydraulic Brake Booster Master Cylinder Stoke Simulator Solenoid Valves Sensors Power Supply Unit Power Supply Unit ECU Capacitor Capacitor Current Model New Model

40. Brake Control System • System Diagram Brake Booster Pump Brake Booster with Master Cylinder Brake Pedal Stroke Sensor Accumulator ABS Motor Relay V Bus No.1 Pump Motor Power Management Control ECU Stroke Simulator Skid Control ECU Speed Sensors Main Body ECU Brake Fluid Level Warning Switch Solenoid Valves ABS Main Relay Power Steering ECU Front Door Courtesy Light Switch (Driver) Regulator Pressure Sensor Yaw Rate & Acceleration Sensor Skid Control Buzzer Wheel Cylinder Pressure Sensor Stop Light Switch Steering Angle Sensor Accumulator Pressure Sensor Stop Light Control Relay Combination Meter

41. Brake Control System • Layout of Main Component Slip Indicator ABS Warning Light Skid Control Buzzer Brake Warning Light Brake Pedal Stroke Sensor Parking Brake Switch Stop Light Control Relay Power Management Control ECU Brake Master Cylinder Reservoir Steering Angle Sensor Stop Light Switch Yaw Rate and Acceleration Sensor Main Body ECU Brake Booster with Master Cylinder - Brake Actuator Brake Booster Pump Assembly Engine Room No.1 Relay Block

42. Brake Control System • Regenerative Brake Cooperative Control • The apportioning of the brake force between the hydraulic brake and the regenerative brake Driver’s Demand Hydraulic Braking Force Braking Force Regenerative Braking Force Time Changes in Braking Force Apportionment

43. Brake Control System • Hydraulic Circuit Brake Master Cylinder Reservoir Accumulator Pump Motor Brake Fluid Level Warning Switch Hydraulic Brake Booster : Accumulator Pressure Sensor Stroke Simulator : Regulator Pressure Sensor Brake Actuator : Wheel Pressure Sensor : Linear Solenoid Valve : Switching Solenoid Valve : Pressure Holding Solenoid Valve : Pressure Reduction Solenoid Valve FR LH FR RH RR LH RR RH

44. Brake Control System • Brake Booster with Master Cylinder • Brake Actuator • Brake actuator that consists of actuator portion and skid control ECU changes the brake fluid path during the operation of brake control Brake Booster with Master Cylinder Brake Actuator

45. Brake Control System • Brake Booster with Master Cylinder • Brake Actuator • Solenoid Valve Operation

46. Brake Control System • Brake Booster with Master Cylinder • Brake Actuator • Solenoid Valve Operation SSC SLA SRC SMC SLR FLH FRH RLH RRH SCC FLR FRR RLR RRR

47. Brake Control System • Brake Booster with Master Cylinder • Brake Actuator • Solenoid Valve Operation

48. Brake Control System • Brake Booster with Master Cylinder • Hydraulic Brake Booster • Hydraulic brake booster generates the hydraulic pressure in accordance with the amount of effort applied to the brake pedal by the driver [Hydraulic Brake Booster Cross Section] Hydraulic Brake Booster

49. Brake Control System • Brake Booster with Master Cylinder • Hydraulic Brake Booster • Structure Reservoir Tank Reservoir Tank Power Piston Accumulator Regulator Piston Operating Rod Booster Chamber Brake Actuator Front Wheel Cylinder Rear Wheel Cylinder Master Cylinder Piston Spool Valve

50. Brake Control System • Brake Booster with Master Cylinder • Hydraulic Brake Booster • Normal Operation From Accumulator Reservoir Tank Reservoir Tank Brake pedal is depressed Booster Chamber To Brake Actuator To Front Wheel Cylinder To Rear Wheel Cylinder