Steering for Your Toyota Alphard Van First Generation (2002-2008)

Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
EPS (Electric Power Steering)  
Motor drives the column shaft  
Power Steering  
ECU  
P/S Warning Light  
[Specification]  
Vehicle Speed  
Sensing Type  
Type  
Steering Column Assembly  
Brushless Motor with  
Gear Ratio (Overall)  
16.5  
3.30  
Rotational Angle Sensor  
Reduction Mechanism  
Hall IC Type Torque Sensor  
No. of Turns Lock to Lock  
Rack Stroke [mm (in.)]  
143.8 (5.66)  
59  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
System Diagram  
Hall IC Type  
Torque Sensors  
Torque Sensor Signals  
Reduction  
Mechanism  
Rotation Angle  
Sensor Signal  
Power  
Steering ECU  
Brushless Motor  
(Resolver Type Rotational  
Angle Sensor included)  
Temp. Sensor  
Boost Converter  
V Bus No.1  
Air  
Combination  
Meter  
Skid Control  
ECU  
DLC3  
ECM  
Conditioning  
Amplifier  
DTC  
Vehicle  
Speed Signal  
Engine  
Speed Signal  
P/S Warning Light  
60  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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]  
Rotation  
Angle Sensor  
Motor  
Wheel  
Gear  
Rotor  
Column  
Shaft  
Torque  
Sensor  
Worm Gear  
Stator  
Torsion Bar  
Input Shaft  
Wheel Gear  
Output  
Shaft  
Column Shaft  
61  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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  
[Torque Sensor]  
Output Shaft  
Motor  
Input  
Shaft  
Yoke  
Multipole  
Magnet  
Torsion  
Bar  
Torque  
Sensor  
Hall ICs  
Torsion Bar  
Input Shaft  
Wheel Gear  
Output  
Shaft  
Column Shaft  
62  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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]  
Magnetic  
Flux  
Input Shaft  
Left Turn  
Right Turn  
(+)  
Hall  
IC1  
Hall  
IC2  
(-)  
Twisted Angle of Torsion Bar (deg)  
Yoke  
: Hall IC1 Signal  
: Hall IC2 Signal  
Output Shaft  
: Neutral Position  
63  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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]  
[Turn to Left]  
[Turn to Right]  
Input Shaft  
Input Shaft  
Input Shaft  
Output Shaft  
Output Shaft  
Output Shaft  
64  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
EPS Operation  
There are the following functions in assist control  
Item  
Function  
Calculates the assist current from the steering torque value and the  
vehicle speed, and actuates the motor  
Basic Control  
Inertia Compensation Improves the starting movement of the motor when the driver starts to  
Control  
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  
Recovery 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  
Damper 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  
System Overheat  
Protection Control  
Cooperative Control  
with EPS  
Controls EPS system in order to facilitate the driver to operate the  
steering in a direction that stabilizes the vehicle during VSC operating  
EPS Electric  
Load Control  
Limits the operation of the electric load when the battery voltage  
decreases  
65  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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  
V Bus No.1  
Power  
Steering ECU  
Loading Control  
OFF  
Level Signal  
Air  
Rear Window  
Defogger  
Conditioning  
Amplifier  
Limitation  
Demand  
66  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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.  
Detection Item  
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  
Torque sensor malfunction  
Illuminate  
Torque sensor power supply abnormal  
Torque sensor zero point adjustment undone  
Torque sensor zero point adjustment incomplete  
Torque hold abnormal  
Illuminate  
Illuminate  
Illuminate  
Illuminate  
Motor malfunction  
Illuminate  
Rotation angle sensor output initialization undone  
Rotation angle sensor output initialization incomplete  
Illuminate  
Illuminate  
67  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
Diagnosis and Fail-safe  
DTC No.  
Detection Item  
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  
Motor rotation angle sensor malfunction  
Illuminate  
Illuminate  
ECU malfunction  
ECU malfunction  
Vehicle speed signal malfunction  
IG power source voltage malfunction  
PIG power supply voltage malfunction  
Power supply relay failure  
Illuminate  
Illuminate  
Illuminate  
Illuminate  
Illuminate  
Illuminate  
Motor relay welding failure  
Assist map number un-writing  
Lost communication with ECM  
Lost communication with brake system control module  
68  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Steering  
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  
Motor overheating  
Power steering ECU internal temperature sensor  
malfunction  
Limits the assist force  
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  
Model Outline  
for Technician  
Engine  
Chassis  
Body  
Body Electrical  
Service Point (Steering)  
Initialization and Calibration  
Perform the initialization and calibration of EPS system  
in the following cases using the intelligent tester  
Assist Map  
Writing  
Rotation angle  
sensor initialization point calibration  
Torque sensor zero  
Power steering  
ECU replaces  
O
-
O
O
O
O
Steering column  
assembly replaces  
Steering effort differs  
between turning left  
and right  
-
O
O
NOTE: Initialization and calibration cannot be performed when the DTCs  
(C1516 and C1526) are stored  
70