LAND CRUISER (100 series) – NEW FEATURES 217

3. VGRS (Variable Gear Ratio Steering) System

General
D A VGRS (Variable Gear Ratio Steering) system, which variably controls the steering angle in accordance
with the driving speed, has been adopted as optional equipment on the model for Europe.
D This system is controlled by the VGRS ECU, which operates the VGRS actuator that is mounted on the
steering intermediate shaft. The operating angle of the actuator is thus added to the steering angle of the
intermediate shaft in order to vary the turning angle of the front wheels in accordance with the vehicle
speed.
D The VGRS ECU is equipped with a diagnosis function and a fail-safe function.

" System Diagram A

ECM

6
Steering Angle
Signal (Main)
Steering
*1 Angle
Skid control ECU *2 Sensor

Vehicle Yaw Rate

Speed VGRS
Sensor Sensor ECU
VGRS
Actuator
*3
Suspension Control ECU

VGRS Warning Light

Steering Gear
DLC3 Assembly

230LX24

*1: VGRS ECU Input Signal (Vehicle speed, Steering Angle (Sub), Steering Wheel Neutral Position)
*2: VGRS ECU Output Signal (VGRS Actuator Operating Angle)
*3: VGRS ECU Output Signal (Steering Wheel Steering Angle + VGRS Actuator Operating Angle)
218 LADN CRUISER (100 series) – NEW FEATURES

Outline of VGRS System

1) General
In the conventional steering system, the gear ratio is set primarily for the high-speed driving mode to
prevent the vehicle from making over-sensitive movements in response to the driver’s steering angle.
For this reason, it requires a large the driver’s steering angle while driving at low speeds.
In the VGRS system, the steering gear ratio can be changed at will. Thus, the VGRS ECU operates the
VGRS actuator in order to constantly realize an optimal gear ratio in accordance with the driving condi-
tions of the vehicle. Thus, it attains a high level of maneuverability and stability between the low- and
the high-speed driving ranges.
D In the extremely low-speed range, which is used when the driver is attempting to park the vehicle, this
system changes the steering gear into the smallest gear ratio in order to reduce the driver’s steering
angle.
D In the low- to medium-speed range, which is used when driving on city streets or on a winding road,
this system changes the steering gear ratio to an optimal level in accordance with the vehicle speed.
As a result, the vehicle responds with more agility and handles more easily.
D In the high-speed range, the steering gear ratio is set to the maximum level to prevent the vehicle from
making over-sensitive movements in response to the driver’s steering angle. Thus, this system ensures
a stable vehicle response.
D If a vehicle that is driven straight ahead over a road surface with different friction coefficients brakes
suddenly and causes the VSC to activate, the vehicle posture becomes disrupted, thus requiring the
driver to operate the steering wheel. When this occurs, the steering gear ratio is rendered even smaller
than that of the ordinary VGRS system in order to reduce the driver’s steering angle.

" Imaginary Diagram of Steering Gear Ratio A

Large
Without VGRS Model

Steering
Gear Ratio

With VGRS Model

Small

Low Speed High Speed

Vehicle Speed
230LX25
 LAND CRUISER (100 series) – NEW FEATURES 219

2) Main Function
D In accordance with the vehicle speed signals that are obtained from the skid control ECU, the VGRS
ECU selects the driver’s steering angle and direction (which are obtained from the steering angle
sensor signals) and the actuator operating angle data (which is preset in the VGRS ECU in accordance
with the vehicle speed). Based on these two pieces of information, the VGRS ECU controls the VGRS
actuator in order to attain the proper actuator target operating angle.
D The VGRS actuator, which is mounted on the steering shaft, rotates constantly in unison with the shaft.
The turning angle of the front wheels is the sum of the optimal operating angle of the VGRS actuator
that the VGRS ECU has determined from the vehicle speed and the angle of the steering wheel that
the driver has steered.
D As shown in the previously mentioned imaginary diagram, the VGRS actuator rotates in the direction
that increases the turning angle of the front wheels in the low-speed range (in which a reduction in the
steering wheel operating effort is desired) or in the medium-speed range (in which a more agile vehicle
response is desired). In the high-speed range (in which an over-sensitive movement response of the
vehicle is not desired), the VGRS actuator rotates in the direction to slightly decrease the turning angle
of the front wheels.
The VGRS actuator rotates only when the driver turns the steering wheel. Furthermore, when the
VGRS actuator rotates in the negative direction, its rotation will not exceed the steering effort of the 6
driver.
D This system contains a lock mechanism. When the VGRS ECU detects a system failure, it stops the
operation of the actuator and locks it to prevent it from rotating. Thus, even if the system fails, the
steering function of the conventional steering system is ensured. To protect the system, this lock
mechanism activates even when the engine is stopped.

Front Wheel
Turning Angle (d)
Effectiveness of
VGRS System

VGRS Actuator (b) Steering

Wheel
(c) (a)

Reduction Mechanism Lock Mechanism

DC Motor

(c) (a)
Front Wheel Steering Wheel
Turning Angle (d) Steering Angle
(b)

VGRS Actuator
Operating Angle

230LX26
220 LAND CRUISER (100 series) – NEW FEATURES

3) Control with a signal from the skid control ECU

If a vehicle that is driven straight ahead over a road surface with different friction coefficients brakes
suddenly and causes the VSC to activate, the vehicle posture becomes disrupted, thus requiring the driver
to operate the steering wheel. When this occurs, the skid control ECU transmits signals to the VGRS
ECU. When the VGRS ECU receives these signals, it calculates the target operating angle for the VGRS
actuator based on the driver’s steering angle and direction (which are obtained from the steering angle
sensor signals) and the vehicle speed signal (which is obtained from the skid control ECU). Then, the
VGRS ECU operates the VGRS actuator to make the steering gear ratio smaller than that during usual
VGRS system operation, thus reducing the driver’s steering ability.

Slippery
Surface

(b)
(a)

(a): Driver’s steering wheel angle by the control with a signal

from the skid control ECU.
(b): Driver’s steering wheel angle by the control without a
signal from the skid control ECU.

230LX27
 LAND CRUISER (100 series) – NEW FEATURES 221

Layout of Main Components

Steering Angle Sensor

VGRS
Warning
Light

Suspension
Control ECU

VGRS ECU

Steering Gear
Skid Control ECU
Assembly 6
VGRS
Actuator
229LC179
Function of Main Components

Components Function
DC Motor Rotates to create the operating angle of the actuator.
Reduction Uses a strain wave gear type reduction mechanism to reduce the rotation of the DC
Mechanism motor to the 1:50 ratio.
Has practically the same construction as the spiral cable that is used for the driver’s
VGRS
airbag of the SRS airbag system. It functions as the contact point for the wiring
Actuator Spiral Cable
harness between the DC motor and the lock solenoid in the rotating actuator and the
VGRS ECU.
Lock Locks the motor shaft so that the DC motor will not rotate in case of a system failure
Mechanism or when the system is stopped due to the stopping of the engine.
Effects comprehensive control of the VGRS system. It primarily controls the
following items:
VGRS ECU D Operates the DC motor by calculating the operating angle of the actuator based on
the signals from the steering angle sensor and the vehicle speed sensor.
D Controls the failsafe function and the diagnosis function.
Detects the steering angle and direction of the steering wheel and transmits them to
Steering Angle Sensor
the VGRS ECU.
Transmits the vehicle speed signal, steering neutral position information, and the
engine speed signal to the VGRS ECU.
Skid Control ECU
Furthermore, it transmits the operating signal to enable this system to effect the
control with a signal from the skid control ECU.
VGRS Warning Light Illuminates to alert the driver if a failure occurs in the VGRS system.
Receives from the VGRS ECU the steered angle of the steering wheel (the sum of the
Suspension Control ECU steered angle of the steering wheel operated by the driver and the operating angle of
the actuator), which is necessary for controlling the active height control suspension.
222 LAND CRUISER (100 series) – NEW FEATURES

Construction and Operation of Main Components

1) VGRS Actuator

a. General
D The VGRS actuator mainly consists of a housing, DC motor, reduction mechanism, spiral cable, lock
mechanism and output shaft.
D The VGRS actuator is integrated with the rubber coupling.

Reduction
Lock Mechanism Mechanism
Output Shaft

Steering Steering
Wheel Gear

DC Motor
Rubber Coupling Spiral Cable 230LX29
Housing

b. DC Motor
D A DC motor that is compact, has high power output, generates less noise, and is brushless, has been
adopted. This DC motor is mounted on the housing.
D This DC motor mainly consists of a magnet, coil, and motor shaft. The motor shaft is coupled to the
wave generator of the reduction mechanism in order to transmit the rotational movement of the motor
to the reduction mechanism.
D This DC motor, which is controlled by the duty cycle signal from the VGRS ECU, rotates either
clockwise or counterclockwise, depending on the steered direction of the steering wheel.
D This DC motor contains an rotational angle sensor. When the VGRS ECU receives the signals from
this sensor, it calculates the operating angle of the VGRS actuator based on the rotational angle and
the rotational direction of the DC motor.

Magnet
Coil

Reduction Mechanism
(Wave Generator)

Motor
View from Top Side Shaft
230LX30
 LAND CRUISER (100 series) – NEW FEATURES 223

c. Reduction Mechanism

i) General
D A strain wave gear type reduction mechanism is used.
D This reduction mechanism mainly consists of a driven gear, stator gear, flexible gear and wave
generator.
D This reduction mechanism reduces the rotation to the 1:50 ratio.

Strain Wave Gear Type

Reduction Mechanism

a. Stator Gear b. Driven Gear c. Flexible Gear d. Wave Generator

230LX31

D The construction of the main components of the reduction mechanism is shown in the table below.

Item Construction
D Has a rigid body, a ring shape, and contains 102 teeth along the inner
circumference.
a Stator Gear
D Positioned parallel with the driven gear.
D Coupled to the housing of the VGRS actuator.
D Has a rigid body, a ring shape, and contains 100 teeth along the inner
Driven Gear circumference.
b
(Output) D Positioned parallel with the stator gear.
D Coupled to the output shaft of the VGRS actuator.
D Has a flexible metal body that forms a belt shape and contains 100 teeth along
the outer circumference.
c Flexible Gear
D Located outside of the wave generator, and positioned in such a way that its gear
teeth are meshed with the inside of both stator gear and driven gear.
D Consists of an oval-shaped cam and a ball bearing that is fitted around the cam.
Wave Generator
d D Coupled to the motor shaft of the DC motor, and rotates inside the flexible gear
(Input)
while pushing the flexible gear against the stator gear and the driven gear.
224 LAND CRUISER (100 series) – NEW FEATURES

ii) Operating Principle of Reduction Mechanism

D The flexible gear is fitted inside the driven gear and the stator gear as illustrated. Furthermore, the
wave generator is fitted inside the flexible gear.
The flexible gear is flexed into an oval shape by the wave generator. The teeth at the long axis of
the oval shape meshes with the teeth of the driven gear and stator gear, and the teeth at the short
axis are disengaged.

Stator Gear Stator Gear

Flexible Gear Driven Gear
Flexible Gear

230LX32
Wave Generator Wave Generator

D For example, if the wave generator (input) rotates clockwise while pushing the flexible gear, due
to the rotational movement of the DC motor, the meshed area of the flexible gear and the driven
gear and stator gear moves in sequence.

230LX33
 LAND CRUISER (100 series) – NEW FEATURES 225

D When the wave generator makes one turn, the flexible gear moves counterclockwise by 2 teeth
because the flexible gear has 2 fewer teeth than the stator gear. The driven gear and the flexible gear
have the same number of teeth, so their rotational movements are identical. Therefore, the driven
gear (output) moves by 2 teeth.

Moves
by 2 teeth

The Driven Gear moves 6

Counterclockwise by
2 teeth.

230LX34

D Due to the aforementioned principle, when the DC motor rotates clockwise, the rotational
movement that is input by the wave generator (which is coupled to the motor shaft) outputs to the
output shaft of the VGRS actuator (which is coupled to the driven gear). As a result, the output shaft
rotates counterclockwise at the 1:50 gear ratio. This rotational angle is added to the actual steered
angle of the steering wheel, thus changing the turning angle of the front wheels.

Housing

Output
Shaft

From
To Steering
Steering
Gear
Wheel

Driven Gear Stator Gear Flexible Gear Wave DC Motor

(100 Teeth) (102 Teeth) (100 Teeth) Generator

230LX35
226 LAND CRUISER (100 series) – NEW FEATURES

d. Lock Mechanism
D This system contains a lock mechanism that mechanically locks the DC motor so that the motor will
not rotate if a failure occurs or when the engine is not running. With this, the housing and the output
shaft become united.
D The lock mechanism is mounted on the DC motor. It consists primarily of a lock holder that is secured
to the motor shaft, a lock lever that is mounted on the housing, and a solenoid that operates the lock
lever.

Lock Holder Solenoid

A A Return Spring

Lock Lever

A – A Cross Section
230LX36

D When the lock mechanism is activated, the VGRS ECU turns OFF the current to the solenoid, and
the return spring pushes the lock lever against the lock holder. Then, the lock lever meshes with the
groove in the lock holder in order to mechanically lock the movement of the DC motor.
When the lock is disengaged, the VGRS ECU turns ON the current to the solenoid, thus disengaging
the lock lever and the lock holder and freeing the movement of the DC motor.

Lock Lever Lock Holder

Solenoid Solenoid
(OFF State) (ON State)
Return Spring

230LX37 230LX38
Lock State Unlock State
 LAND CRUISER (100 series) – NEW FEATURES 227

e. Spiral Cable
D The construction of the spiral cable is almost identical as that of the one used for the driver’s airbag
of the SRS airbag system. It functions as the contact point for the wiring harness between the DC
motor and the lock solenoid in the rotating actuator and the VGRS ECU.
D This spiral cable is mounted above the housing.
D The spiral cable is an internal flexible flat cable with a dual winding construction, which consists of
two systems: the power system and the signal system.
D The operating range of this spiral cable is 5.0 turns.

Flexible Flat Cable

230LX39
Cross Section

Service Tip

If the VGRS actuator must be removed from the vehicle and reinstalled or disconnect the steer-
ing linkage, it is necessary to verify the neutral position of the spiral cable for VGRS System
and spiral cable for SRS Airbag System. For details, refer to the Land Cruiser Chasis and Body
Repair Manual Supplement (Pub. No. RM970E).
228 LAND CRUISER (100 series) – NEW FEATURES

2) Steering Torpue Transmission

a. Low and Middle Speed Range

This system rotates the VGRS actuator in the positive direction in the low-speed range (in which a
reduction in the steering wheel operating effort is desired) or in the medium-speed range (in which a
more agile vehicle response is desired).
For example, if the driver turns the steering wheel clockwise, the torque is transmitted as illustrated
below.
In order to create the target operating angle for the actuator that has been determined by the VGRS ECU,
the DC motor in the VGRS actuator rotates counterclockwise. Then, the rotational movement of the
DC motor is input into the reduction mechanism by way of the wave generator. The rotational
movement is reduced to a 1:50 gear ratio, and is output from the output shaft in the clockwise direction.
This operating angle of the VGRS actuator is then added to the angle in which the steering wheel is
steered by the driver. Thus, the intermediate shaft rotates more clockwise than the steered angle of the
steering wheel by the amount of the operating angle of the VGRS actuator. As a result, the front wheels
turn more to the right.

DC Motor
Output VGRS Actuator
Shaft

Effectiveness
of VGRS
System

Wave
Generator

VGRS Actuator
Steering Wheel VGRS Actuator
Operating Angle
Steering Wheel
Steering Angle Operating Angle
(Positive Direction) Steering Angle

230LX40
 LAND CRUISER (100 series) – NEW FEATURES 229

b. High Speed Range

In the high-speed range (in which an over-sensitive movement response of the vehicle is not desired),
the VGRS actuator of this system rotates slightly in the negative direction.
For example, if the driver turns the steering wheel clockwise, the torque is transmitted as illustrated
below.
In order to create the target operating angle for the actuator that has been determined by the VGRS ECU,
the DC motor in the VGRS actuator rotates clockwise. Then, the rotational movement of the DC motor
is input into the reduction mechanism by way of the wave generator. The rotational movement is
reduced to a 1:50 gear ratio, and is output a little from the output shaft in the counterclockwise direction.
This operating angle of the VGRS actuator is then subtracted from the angle in which the steering wheel
is steered by the driver. Thus, the intermediate shaft rotates less clockwise than the steered angle of the
steering wheel by the amount of the operating angle of the VGRS actuator. As a result, the front wheels
turn less to the right.
When the VGRS actuator rotates in the negative direction, it will not rotate in excess of the driver’s
steering angle.

6
DC Motor

Effectiveness
of VGRS
System

Wave
Generator

VGRS Actuator
Steering Wheel VGRS Actuator Operating Angle Steering Wheel
Steering Angle Operating Angle
(Negative Direction) Steering Angle

230LX41
230 LAND CRUISER (100 series) – NEW FEATURES

3) VGRS ECU
a. General
D In accordance with the vehicle speed signals that are obtained from the skid control ECU, the VGRS
ECU selects the driver’s steering angle and direction (which are obtained from the steering angle
sensor signals) and the actuator operating angle data (which is preset in the VGRS ECU in
accordance with the vehicle speed). Based on these two pieces of information, the VGRS ECU
controls the VGRS actuator in order to attain the proper actuator target operating angle.
D The VGRS ECU is located near the area where the brake pedal is mounted.
D The VGRS ECU stores in its memory the neutral position of the VGRS actuator that has been
determined as desired. Thus, the VGRS ECU effects control by using this neutral position as a
reference. Furthermore, the VGRS ECU constantly stores in its memory the operating angle of the
VGRS actuator. These data that have been stored in memory will not be erased even if the battery
terminals are disconnected.
D The VGRS ECU is equipped with a diagnosis function and a fail-safe function.
Service Tip
The VGRS ECU stores in its memory the neutral position of the VGRS actuator that has been
determined as desired. If the VGRS ECU or the VGRS actuator must be replaced, it is necessary
to correct the neutral position with respect to the operating angle of the VGRS actuator.
For details, refer to the Land Cruiser Chasis and Body Repair Manual Supplement (Pub. No.
RM970E).

b. Diagnosis
D If the VGRS ECU detects a malfunction in the VGRS system, it will immediately stop the operation
of the system, and illuminate the VGRS warning light that is provided in the combination meter in
order to alert the driver.
At the same time, the DTC (Diagnostic Trouble Code) are stored in memory.
The DTC can be read by connecting the SST (09843-18040) between the Tc and CG terminals of
DLC3 and observing the blinking of the VGRS warning light or by connecting a hand-held tester.
D The table below indicates the DTCs that are associated with this system. For details concerning the
DTCs, see the Land Cruiser Chasis and Body Repair Manual Supplement (Pub. No. RM970E).
DTC No. Detection Item DTC No. Detection Item
Steering Angle Sensor
C1511 / 11 C1551 / 51 IG Power Source Voltage Malfunction
Malfunction
VGRS Actuator Neutral DC Motor Power Source voltage
C1515 / 15 C1552 / 52
Position undone Malfunction
VGRS Actuator Neutral
C1516 / 16 C1554 / 54 Power Source Relay Failure
Position undone
C1521 / 21 VGRS Actuator Malfunction C1555 / 55 Predriver Source Relay Failure
C1522 / 22 VGRS Actuator Malfunction C1561 / 61 Lock Mechanism Malfunction
Lock Mechanism Insertion
C1527 / 27 VGRS Actuator Malfunction C1567 / 67
Malfunction
C1528 / 28 VGRS Actuator Malfunction C1568 / 68 Lock Holder Deviation Detection
C1531 / 31 VGRS ECU Malfunction C1569 / 69 Lock Mechanism Release Incomplete
Vehicle Speed Sensor Malfunction
C1532 / 32 VGRS ECU Malfunction C1571
(FLO)
Vehicle Speed Sensor Malfunction
C1533 / 33 VGRS ECU Malfunction C1572
(FRO)
Skid Control System
C1541 / 41 C1575 Steering Angle Sensor Malfunction
Malfunction
Skid Control System DC Motor Revolution Angle Sensor
C1549 / 49 C1576
Communication Malfunction Malfunction
 LAND CRUISER (100 series) – NEW FEATURES 231

c. Fail-Safe
D If the VGRS ECU detects a malfunction in the VGRS system, it will take the actions indicated in the
table below.
D The VGRS ECU has a built-in temperature sensor in order to effect failsafe control if it overheats.
Furthermore, this ECU monitors any changes in the actuating voltage of the DC motor in order to
detect the overheating of the motor.

VGRS DTC
Malfunction Item Description of Control Warning Memory
Light*1 Condition*2
Steering Angle Sensor Malfunction Stops the control f f
DC Motor Malfunction " f f
VGRS ECU Malfunction " f f
DC Motor Circuit Malfunction " f f
Lock Mechanism Circuit Malfunction " f f
Vehicle Speed Signal Malfunction " f f
Skid Control ECU Communication
Signal Malfunction
" f f 6
First, the control is stopped; then, the
DC Motor Overheat control resumes after the system — —
resumes its normal operation.
VGRS ECU Overheat " — —
PIG Power Source Drop Voltage
" — —
Malfunction
VGRS Actuator Malfunction*3 " — —
*1: f = VGRS Warning Light lights up
— = VGRS Warning Light does not light up.
*2: f = Memorize
— = None
*3: Specific Examples:
(1) When the steering is 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 it has been steered entirely to
the rack end.