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Avensis

Avensis. Chassis. Contents. Clutch EA6# Manual Transaxle EB60 / EC60 Manual Transaxle Gear Shift Indicator System K111 CVT (Continuously Variable Transaxle) K311 CVT (Continuously Variable Transaxle) Brake Brake Control System Electric Parking Brake Steering. Clutch. Subtitle.

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Avensis

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  1. Avensis Chassis Footer detail

  2. Contents • Clutch • EA6# Manual Transaxle • EB60 / EC60 Manual Transaxle • Gear Shift Indicator System • K111 CVT (Continuously Variable Transaxle) • K311 CVT (Continuously Variable Transaxle) • Brake • Brake Control System • Electric Parking Brake • Steering Footer detail

  3. Clutch • Subtitle Footer detail

  4. Clutch • CSC (Concentric Sleeve Cylinder) [EB60 and EC60] • CSC has combined the functions of clutch release cylinder and clutch release bearing for excellent clutch feeling [CSC Type] [Conventional Type] Clutch Release Cylinder (With Bleeder Plug) From Master Cylinder Clutch Bleeder Clutch Release Fork Release Fork Support Clutch Release With Bearing Cylinder (CSC Type) Clutch Release Bearing Footer detail

  5. Clutch Bearing Clutch Bleeder • CSC (Concentric Sleeve Cylinder) [EB60 and EC60] • Construction Spring From Clutch Master Cylinder Housing Piston Seal Piston Clutch Release With Bearing Cylinder (CSC Type) The clutch release with bearing cylinder cannot be disassembled Footer detail

  6. Piston moves to the engine side The piston seal may be damaged by foreign matter Replace new one Service Point (Clutch) • CSC (Concentric Sleeve Cylinder) [EB60 and EC60] • Service Precaution • When the transaxle is removed from the engine, replace the clutch release with bearing cylinder assembly with a new one Transaxle is removed from the engine Piston Seal Clutch disc wears Foreign Matter Footer detail

  7. Service Point (Clutch) • CSC (Concentric Sleeve Cylinder) [EB60 and EC60] • Service Precaution • When the seal bolts are removed, replace them with new ones 3 Seal Bolts (Non-reusable) Footer detail

  8. Service Point (Clutch) • CSC (Concentric Sleeve Cylinder) [EB60 and EC60] • Service Precaution • The clutch fluid should be replaced according to the Maintenance Schedule Footer detail

  9. EA6# Manual Transaxle • Subtitle Footer detail

  10. EA6# Manual Transaxle • Specifications *1: For 1st to 4th *2: For 5th, 6th, Reverse *3: With the oil fully filled Footer detail

  11. EB60 / EC60 Manual Transaxle • Subtitle Footer detail

  12. The ball and spring in the synchromesh shifting key are combined into one unit to improve shift feeling Plastic pad for the shift fork reduces the sliding resistance (Same as EA6#) Low friction bearings improve torque transmission efficiency Pre-synchronizing system prevents gear noise Oil separators reduce energy loss • Select cable length adjustment mechanism (Same as EA6#) • Pull collar type shift lever (Same as EA6#) EB60 / EC60 Manual Transaxle • Overall • EB60 / EC60 6-speed manual transaxle is newly developed Footer detail

  13. EB60 / EC60 Manual Transaxle • Specifications *1: 1ZR-FAE *3: For 1st to 4th *5: With the oil fully filled *2: 2ZR-FAE *4: For 5th, 6th, Reverse Footer detail

  14. EB60 / EC60 Manual Transaxle • Identification Information • The transaxle serial number is stamped on the case as shown in the illustration Transaxle Serial Number Footer detail

  15. Ball Spring Synchromesh Shifting Key EB60 / EC60 Manual Transaxle • Synchromesh Shifting Key • The ball and spring are combined into one unit, thus ensuring the stable position of the synchromesh shifting and improving shift feeling Footer detail

  16. EB60 / EC60 Manual Transaxle • Oil Separator • The oil separator prevents the oil from being directly mixed by the gears, thereby reducing agitation resistance Oil Catch Tank Oil Separator Footer detail

  17. R 1 3 5 2 4 6 2 1 3 2 1 2 4 3 EB60 / EC60 Manual Transaxle • Pre-synchronizing System • While reverse is selected, synchromesh mechanism of 6th gear is activated to reduce gear noise Reverse Pre-balk Head No. 1 Reverse Selected Shift and Select Lever Shaft Reverse Pre-balk Head No. 2 Protrusion Portion Shift Fork Shaft No. 3 Reverse Pre-balk Head No. 3 A View From A 6th Gear Protrusion Footer detail

  18. EB60 / EC60 Manual Transaxle • Transmission Control Select Cable • Select cable with cable length adjustment mechanism is used to improve serviceability Shift Cable Shift Lever Assy Select Cable Temporary Illustration Adjustment Portion Footer detail

  19. Temporary Illustration 3. Fix the outer select lever in 1st / 2nd position 5. Move the shift lever to 1st/2nd direction 7. Free the outer select lever 1. Disconnect the select cable 2. Release the cable lock 6. Lock the cable lock 4. Connect the select cable Service Point (EB60 / EC60 Manual Transaxle) • Adjustment for Transmission Control Select Cable • Outline of adjustment procedure Footer detail

  20. 2. Release the cable lock (a) Twist the stopper Stopper (b) Pull out the lock piece (c) Return the stopper 1. Remove the clip and disconnect the select cable Service Point (EB60 / EC60 Manual Transaxle) • Adjustment for Transmission Control Select Cable • 1. Disconnect the select cable • 2. Release the cable lock Footer detail

  21. EB60 EC60 (a) Hook the outer select lever to the reverse restrict pin (a) Align the hole Outer Select Lever Transaxle Case Hole Outer Select Lever (b) Insert a bolt into the aligned holes Reverse Restrict Pin Service Point (EB60 / EC60 Manual Transaxle) • Adjustment for Transmission Control Select Cable • 3. Fix the outer select lever in 1st / 2nd position Footer detail

  22. Temporary Illustration 5. Move the shift lever to 1st/2nd direction R 1 3 5 4. Connect the select cable, and install the clip 2 4 6 Service Point (EB60 / EC60 Manual Transaxle) • Adjustment for Transmission Control Select Cable • 4. Connect the select cable • 5. Move the shift lever to 1st/2nd direction Footer detail

  23. EB60 6. Lock the cable lock (a) Twist the stopper 7. Remove the bolt to free the select outer lever Stopper EC60 (b) Push the lock piece into the case 7. Move the shift lever to R, and free the outer select lever Reverse (c) Return the stopper Service Point (EB60 / EC60 Manual Transaxle) • Adjustment for Transmission Control Select Cable • 6. Lock the cable lock • 7. Free the outer select lever Footer detail

  24. Gear Shift Indicator System • Subtitle Footer detail

  25. 3rd Upshift Recommendation Comparison Actual Gear Position 4th 3rd 4th VPA SPD “Recommended Gear Position” (Good Environmental Performance Gear Position) Gear Shift Indicator System • Outline • This system shows a guideline to help the driver achieve good environmental performance driving Footer detail

  26. ECM Vehicle Speed Crankshaft Position Sensor V Bus No. 1 Shift Diagram for Gear Shift Indicator Accelerator Pedal Position Sensor Gear Shift Indicator Backup Light Switch Combination Meter Electric Parking Brake ECU Stop Light Switch Clutch Pedal Stroke Sensor Gear Shift Indicator System • System Diagram • ECM controls the gear shift indicator Footer detail

  27. Combination Meter A Portion B Portion • Upshift Recommendation • Downshift Recommendation • Good gear position is used • Bulb Check • (From IG ON to Engine Start) Gear Shift Indicator System • Gear Shift Indicator • The display shows following condition Footer detail

  28. Comparison VPA SPD Gear Shift Indicator System ECM • System Operation (Basic Operation) • ECM compares the actual gear position with the “recommended gear position” Engine Speed Actual Gear Position Vehicle Speed “Recommended Gear Position” Upshift/ Downshift Recommendation Accelerator Pedal Opening Angle Footer detail

  29. Gear Shift Indicator System • System Operation (Control in Uphill Traveling) • At uphill traveling, this control reduces the upshift recommendation in order to ensure a comfortable drivability [For Example] 6th 4th 5th 3rd 5th 4th 5th Without Control 6th 4th 3rd 4th With Control “Recommended Gear Position” Footer detail

  30. ECM Prohibit upshift recommendation Driver requires engine brake Release Speed Quickly release Position Up 3rd Accelerator pedal VPA 5th SPD Gear Shift Indicator System • System Operation (TA Control) • When the accelerator pedal is quickly released, this system does not show the upshift recommendation No Recomme-ndation Footer detail

  31. Gear Shift Indicator System • Operation Condition • When the vehicle is following condition, this system does not operate Clutch is disengaged OFF Speed Limiter Function (Cruise Control System) is operating Footer detail

  32. K111 CVT (Continuously Variable Transaxle) • Subtitle Footer detail

  33. K111 CVT (Continuously Variable Transaxle) • Transaxle Type • K111 • Overall • A metal belt type continuously variable transaxle with electronic hydraulic control • Engine Type • 3ZR-FAE (2.0 L) • Shift Mechanism Type • Pulley and Steel Belt • Forward/Reverse Switching Mechanism • Single Pinion Type Planetary Gear • Gear Ratio • Forward • 2.396 to 0.428 • Reverse*1 • 1.668 • Differential Gear Ratio*2 • 5. 182 • Shift Lever Position • P – R – N – D – M • Fluid Type • CVT Fluid TC • Fluid Capacity • [Liter (US qts, Imp. qts)] • 8.6 (9.09, 7.57) • Weight (Reference) • ??? *1: Planetary Gear Ratio Included *2: Reduction Gear Ratio Included Footer detail

  34. General AT 1st 2nd 3rd 4th Engine Speed CVT (Shaded Region) Vehicle Speed Speed Ratio K111 CVT Secondary Pulley Pulley Width = Wide Pulley Width = Narrow • Features of CVT • CVT perform speed ratio control using a pair of pulleys Metal Belt Primary Pulley INPUT OUTPUT Pulley Width = Narrow Pulley Width = Wide Low Speed Ratio High Speed Ratio Operation of CVT Footer detail

  35. : CVT • : General AT Optimal Fuel Consumption Enlarged Fuel Cut Area Specific Fuel Consumption Map Speed Ratio Control Area for CVT 1st 2nd 3rd 4th Engine Torque Engine Speed ON Fuel Cut OFF Vehicle Speed Engine Speed Enlargement of fuel cut area when deceleration Area used when driving K111 CVT • Features of CVT • Driving near optimal fuel consumption is allowed Footer detail

  36. : CVT • : General AT K111 CVT • Features of CVT • Engine speed in a high output range can be maintained Maximum Engine Output Point Engine Speed Time Engine Speed During Full Throttle Acceleration Footer detail

  37. : CVT • : General AT Effective Driving Force Area in CVT K111 CVT • Features of CVT • Smooth driving force characteristics High Driving Force High Vehicle Speed Chart of Driving Force Characteristics Footer detail

  38. K111 CVT Forward and Reverse Drive Shift Mechanism Torque Converter with Lock-up Clutch • Components Primary Pulley Continuously Variable Transaxle and Metal Belt Metal Belt Oil Pump Secondary Pulley Reduction Gear Parking Lock Mechanism Differential Gear Footer detail

  39. Pattern Select Switch 3 Speed Sensors CVT Fluid Warmer Oil Pressure Sensor Overflow Plug Valve Body Unit (Hydraulic Control Unit) Shift Position Indicator (Combination Meter) K111 CVT • Components Footer detail

  40. Secondary Pulley Forward and Reverse Drive Shift Mechanism Torque Converter with Lock-up Clutch Metal Belt Primary Pulley CVT Fluid Warmer K210 CVT Reference (K111 CVT) • Components (K210 CVT) Footer detail

  41. K111 CVT • Identification Information • The transaxle serial number is stamped on the case as shown in the illustration Transaxle Serial Number Footer detail

  42. Turbine Runner Lock-up Clutch Pump Impeller Stator Damper Structure One-way Clutch K111 CVT • Torque Converter with Lock-up Clutch • Damper structure allowing lock-up from low speed range Footer detail

  43. K111 CVT • Oil Pump • The oil pump is combined with the torque converter, lubricates the parts and • supplies operating pressure to the hydraulic control Oil Pump Footer detail

  44. Reverse Brake Input Shaft Primary Pulley Metal Belt Forward Clutch Secondary Pulley Planetary Gear Unit Reduction Gear Continuously Variable Transaxle Differential Ring Gear K111 CVT • Gear Train • Consists of a planetary gear, continuously variable transaxle, reduction gear and differential gear Footer detail

  45. D position (Lowest Ratio) D position (Highest Ratio) Pulley Width = Wide Pulley Width = Narrow OFF OFF ON ON Pulley Width = Narrow Pulley Width = Wide K111 CVT • Gear Train • Operation (D Position) Footer detail

  46. N position R position Pulley Width = Wide Pulley Width = Wide OFF ON OFF OFF Pulley Width = Narrow Pulley Width = Narrow K111 CVT • Gear Train • Operation (N and R Position) Footer detail

  47. K111 CVT • Continuously Variable Transaxle and Metal Belt • Performs speed ratio control by varying the pulley width with piston operation of the primary and secondary pulleys Metal Belt Primary Pulley Secondary Pulley Footer detail

  48. Primary Pulley Secondary Pulley Hydraulic Chamber Before Stroke During Stroke Double Piston Structure K111 CVT • Continuously Variable Transaxle and Metal Belt • The primary pulley uses double piston construction to reduce the diameter of hydraulic chamber Footer detail

  49. Metal Belt Steel Ring (Two Lines) Element K111 CVT • Continuously Variable Transaxle and Metal Belt • The metal belt allows power transmission with the compressive effect of element (element extrusion) Footer detail

  50. Forward Clutch (With Centrifugal Fluid Pressure Canceling Mechanism) Reverse Brake K111 CVT • Forward and Reverse Drive Shift Mechanism • A single pinion type planetary gear is used Footer detail

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