Daihatsu Move Teardown (Part 1): Equipment comparable to B-segment cars

Suppliers list, chassis, seats, and electrical components

2015/02/19

Summary

Daihatsu Move

 The Daihatsu Move teardown was held on January 21 through 27, 2015, by the Hiroshima Industrial Promotion Organization. The teardown event was performed by the Hiroshima Kokusai Gakuin Automotive Junior College in Hiroshima Prefecture, Japan. The fifth-generation Daihatsu Move X-turbocharged VS grade was used in the benchmarking event. The model was built in 2014 and fitted with Smart Assist crash avoidance system,

 Mini vehicles are often considered synonymous with low-cost cars. However, the teardown proved that the Daihatsu Move was par with, if not better than, the B-segment cars in terms of specifications. All parts were manufactured with true craftsmanship to ensure competitiveness in performance and quality. To deliver quality performance and comfortable riding experience, for instance, costs are duly allotted to the chassis and seat frame that are normally unseen by users. The chassis suspension components are comparable with those found in larger and heavier B-segment vehicles. The seat frame has two S-springs in both the cushion and seatback, which makes the Daihatsu Move superior to a B-segment car. These support the riding comfort and quietness that the car is reputed for. The torn down model, the Daihatsu Move X-turbocharged VS grade Smart Selection SA (Smart Assist) version is equipped with a Vehicle Stability Control (VSC) system and emergency brake assist which uses front-mounted laser sensors. This report (Part 1) contains a list of parts suppliers and describes the parts that are directly related to the Move's basic performance and safety features.

Previous teardown reports:

VW Polo (Dec. 2014)
(Part 1) Engine compartment and driver's seat area
(Part 2) 1.2-liter TDI diesel engine and suspensions
Nissan Note (Sep. 2014)
(Part 1) Major safety technology and advanced driver assistance systems
(Part 2) Drive unit and supercharger
Honda Accord Hybrid (Feb. 2014)
(Part 1) PCU and vehicle chassis components
(Part 2) Battery components and electric servo brake system
(Part 3) Sport Hybrid i-MMD drive unit
Honda Fit Hybrid (Dec. 2013)
(Part 1) Battery components & brake system
(Part 2) Engine and transmission
Toyota Aqua (Prius c) (Nov. 2012)
(Part 1) Part suppliers and battery components
(Part 2) Hybrid systems behind the 35.4km/liter car
Nissan Leaf
(Part 1) Benchmarking systems and components for EV (Mar. 2012)
(Part 2) Main components disassembled (Sep. 2012)

Specifications of the 2014 Daihatsu Move

Daihatsu Move Daihatsu Move
Vehicle specifications Model name/Grade the Daihatsu Move X-turbocharged VS grade (special version with Smart Selection SA (Smart Assist)
Price JPY 1.33 million plus JPY 60,000 for the optional Smart Assist
Dimensions Length: 3,395mm, Width:1,475mm, Height: 1,620mm
Curb Weight 820kg
Seating capacity 4 including driver's
Engine KF-type inline 3-cylinder intercooler turbo
Transmission Torque converter and CVT with lockup mechanism
Fuel efficiency (JC08 mode) 25.20km/L


Key parts suppliers

Component Supplier
Engine Engine ECU Denso
Turbocharger IHI
Intercooler T.RAD
Ignition coil Diamond Electric MFG.
Crankshaft rotation sensor Diamond Electric MFG.
Camshaft rotation sensor Continental (Made in China)
Knock sensor Denso
O2 sensor (in front of catalytic converter) Denso
O2 sensor (behind catalytic converter) Denso
EGRvalve Denso
Oil filter Denso
Starter motor Denso
Alternator Denso
Accelerator pedal position sensor Denso
Air cleaner Roki
Exhaust assembly Futaba Industrial
Exhaust muffler Futaba Industrial
Exhaust tube Futaba Industrial
Three-way catalytic converter Futaba Industrial
Power train Transmissison ECU Fujitsu Ten
Driveshaft (on the right) NTN
Driveshaft (on the left) NTN
Chassis Front suspension strut Hitachi Automotive Systems
Rear shock absorber Hitachi Automotive Systems
Steering gear Akashi Kikai Industry
Electric power steering JTEKT
Motor Denso
ECU Furukawa Electric
Steering lock Tokai Rika
Front hub bearing NTN (Made in Japan)
Front brake caliper Hitachi Automotive Systems
Rear drum brake Nisshinbo Brake
Brake booster and master cylinder Advics
Front brake hose Toyoda Gosei
Tire (155 / 65R14 75S) Sumitomo Rubber Industries
Fuel systems Fuel hose (between tank and tube) Sanoh Industrial
Fuel tank sensor harness Furukawa Electric
Fuel pump Denso
Canister Aisan Industry
HVAC and Cooling systems Air conditioner compressor Denso
Radiator T.RAD
Radiator sub-tank Toyoda Gosei
Safety equipment Air bag inflator (Driver-side) Nippon Kayaku
Air bag (Front passenger-side) Takata
Air bag ECU Denso
Front seat belt (with pre-tensioner) Takata
Rear seat belt Ashimori Industry
Electrics VSC Gsensor/yaw rate sensor Denso
VSC Unit Advics
Hydraulic actuator Advics
ECU Advics
Razor sensor for emergency brake systems Denso
Keyless entry system ECU Tokai Rika
Buzzer for parking sensor HDK
Combination meter Denso
Head lamp assembly Stanley Electric
Turn lamp valve Stanley Electric (Made in Japan)
High/Low beam valve OSRAM (Made in Germany)
Aiming beam adjust system Koito Manufacturing
Rear combination lamp Ichikoh Industries (Made in Kyushu, Japan)
Horn Maruko Keihoki
Battery GS Yuasa International
Fuse box Sumitomo Wiring Systems/Sumitomo Electric Industries
Relay box Sumitomo Wiring Systems/ Sumitomo Electric Industries
Wire harness assembly Sumitomo Wiring Systems/ Sumitomo Electric Industries
Engine room harness Sumitomo Wiring Systems/ Sumitomo Electric Industries
Instrument panel harness Sumitomo Wiring Systems/ Sumitomo Electric Industries
Body harness Sumitomo Wiring Systems/ Sumitomo Electric Industries
Window washer tank Asmo
Body Front glass Asahi Glass
Rear glass Asahi Glass
Front door glass Asahi Glass
Rear door glass Nippon Sheet Glass
Front corner window glass Nippon Sheet Glass
Rear side glass Nippon Sheet Glass
Front door regulator Denso
Front door lock/Inside handle Aisin Seiki
Hood opener cable HI-LEX
Others Tire repair kit Sumitomo Rubber Industries (Made in Kobe, Japan)
Air compressor (For tire repair) Ohashi Sangyo (Made in China)

 

 



Chassis components comparable with those on B-segment cars

 The Move uses conventional suspensions of ordinary front-wheel drive vehicles with MacPherson strut type front suspension and torsion beam type rear suspension. But they are comparable with those on B-segment vehicles in terms of size and layout. In addition, the Move has ventilated disc brakes in the front.

 

Front suspension

Front strut suspension Front suspension, steering and brake assembly
Front strut suspension Front suspension, steering and brake assembly


Struts comparable with those on B-segment cars in size
 The front strut has an outside diameter of 45mm and a piston rod diameter of 18mm, both larger than those of a B-segment car. The larger strut design leads to a higher lateral rigidity and less alignment change. This, in turn, leads to better straight travel stability and more accurate response to steering. The large shock absorber leads to a less tight internal structure with a greater potential of agile and good dampening characteristics.

Lightweight and compact suspension member with full consideration for performance
 The front suspension member on the Move is of the conventional configuration as on the Volkswagen Polo reported in our previous teardown reports. It is compact and simple in design but full consideration is given to performance and quality. It is designed to ensure optimal suspension geometry, lateral suspension rigidity and rigidity at body attachment in consideration of handling stability, riding comfort and quietness. The transverse link to steering gear attachment and the attachment to the rear body are attached to one flat suspension member. This design enables lightweight and compact suspension member without compromising on rigidity. It ensures proper integrity with the body without the use of additional reinforcements. This is important for steering stability as the alignment change is minimal when a large force is transmitted from road surfaces via wheels to the suspension. The high coupling rigidity with the vehicle body also means less vibrations. This also helps reduce the transmission of the tire noises to the body.

 

Strut, spring and bumper rubber Suspension member and transverse link (RH)
Strut, spring and bumper rubber Suspension member and transverse link (RH)

 

Rear suspension

 The rear suspension on the Move is of the conventional torsion beam type, but all rear suspension components are nearly the same in size as those on B-segment vehicles. The Move uses a semi-independent type torsion beam suspension. The beam twists when a force from the road is applied to one of the wheels. In this way, it prevents the external force from being transmitted to the other wheel. The twisting beam also functions as a stabilizer that suppresses the roll when cornering. To strengthen the stabilizing function, a torsion bar is located inside the torsion beam. The trailing arm is attached directly to the highly rigid rear side member (body). This design gives higher bearing rigidity to the suspension and ensures greater handling stability. The proximity of the suspension to the highly rigid portion of the body also blocks noise and vibrations from the road surfaces more easily. The rear shock absorber has an external cylinder diameter of 32mm and the piston rod diameter of 10mm. They are nearly the same size as those of the B-segment vehicles and give better dampening performance to the shock absorber.

 

Torsion beam suspension (top) Torsion beam suspension (bottom) with a built-in stabilizer
Torsion beam suspension (top) Torsion beam suspension (bottom) with a built-in stabilizer

 

Trailing arm to body (side member) attachment Rear shock absorber (external cylinder diameter:  32mm)
Trailing arm to body (side member) attachment Rear shock absorber (external cylinder diameter: 32mm)

 

Steering column and electric power steering

Steering column Steering column
Steering column (integrated with electric power steering)


 The Daihatsu Move uses a column assist electric power steering system in which the motor is integrated with the steering column shaft. This design is preferred when there is not enough space near the suspension member in the engine compartment for locating the motor on the steering rack. This design is also preferred because of the simple structure that reduces the cost compared to the steering rack drive type. However, an intermediate joint is used between the motor and the steering gear and this creates a slight backlash and play. This presents a drawback for the column type power steering in terms of steering reactive torque and smooth, natural response to steering.

 The steering lock function is controlled electronically by a push-to-start keyless entry system.

 

Front ventilated disc brakes

 The Move is fitted with the fist type brake caliper (supplied by Hitachi Automotive) having a piston diameter of 50mm and a ventilated disc brake having a disc diameter of 234mm and thickness of 16mm. This combination is more than sufficient for a turbocharged vehicle having a vehicle weight of only 820kg.

 

Front brake Front brake Front brake
Front brake (fist type caliper piston diameter 50mm, ventilated disc diameter 234mm and thickness 16mm)

 

Rear brakes

 Rear leading/trailing drum brakes

 The Move is fitted with the common leading/trailing drum brakes.

 

Rear leading/trailing type drum brakes Rear leading/trailing type drum brakes
Rear leading/trailing type drum brakes

 

Engine mounts

 The Move has a hydraulic fluid-filled engine mount on the right side of the vehicle. An engine mount must isolate the chassis from engine vibration and noise by absorbing them in rubber of appropriate properties. At the same time, it must constrain resonance phenomena with the vibration from the suspension and the chassis. Engine mount tuning is not easy as contradicting requirements must be met. The hydraulic fluid-filled engine mount uses the fluid to dampen vibration. This provides better isolation of noise and vibration than the solid rubber type engine mount. The hydraulic fluid-filled engine mount costs more than the solid rubber type engine mount but is a better solution in terms of quietness, riding comfort and driving stability.

 

Hydraulic fluid-filled engine mount Hydraulic fluid-filled engine mount
Hydraulic fluid-filled engine mount (installed on right side of the vehicle)

 
 The left-side engine mount (near the transmission) is of the conventional solid rubber type. It uses a plenty volume of rubber and a large stroke against large force. It is well designed to ensure optimal vibration characteristics by changing the rubber volume and hardness and a gap between rubbers according to the direction of vibration (vertical, longitudinal, lateral).

Solid rubber type engine mount Solid rubber type engine mount
Solid rubber type engine mount (installed on left side of the vehicle near the transmission)

 

 



Luxurious front seat has two S-springs each in cushion and back

Seat frame Seat lifter
Seat frame with a  pair of S-springs each in the cushion and the back The seat lifter is used to adjust the seat height.
The seat base is fabricated separately so that the frame can be used on vehicles of different heights.

 

Seatback Seat cushion Armrest with a storage box
Seatback Seat cushion Armrest with a storage box


 Above are photos of the seat frame with the urethane pad removed. A pair of S-springs are used each in the seatback and the seat cushion. This presents an ideal frame structure as it produces an unstrained cushion stroke that is not available from a urethane pad alone. Some B-segment cars have only a single spring for cost reduction purpose. Some models have urethane pad cushion without a spring. The Daihatsu Move is fitted with a ride quality-oriented seat that is rare for mini vehicles.

 The Move is also fitted with a seat lifter which is not found on most mini or low-priced vehicles. It allows changing the height not only of the seat cushion but of the entire seat as well. Seat lifters are used in certain B-segment vehicles, but some of them only allow changing the cushion height. In that case, changing the cushion height affects the positional relation between the cushion and the seatback. As a result, the driver will not be able to adjust the seat to suit his/her body position properly. The seat frame on the Move is a perfect solution in this regard.
   As a means of cost reduction, the seat frame is divided into the seat and the pedestal (painted black in the photo) sections. The seat frame is shared by various models including variants. Daihatsu changes the height of the lower-cost pedestal as needed to meet different seat height requirements for each model. The use of lower-cost pedestal and volume production of seat frames seem to be the way of cost reduction.



Full lineup of auxiliary electrical equipment

 There is no significant difference between mini vehicles and compact vehicles today in terms of the grades of electric equipment used. The Road Transport Vehicle Act was revised on October 1, 2014, after which the Vehicle Stability Control (VSC) and Brake Assist System (BAS) are required on all new models. Those systems are already made available as standard or options by all carmakers although a respite for the system deployment is granted until February 24, 2018, on on-going production models. The VSC and the BAS are used in the Daihatsu Move along with such safety systems as the emergency brake assist and emergency brake warning. The Move is also fitted with the push-to-start keyless entry system, back sonar and other convenience-oriented systems. Sensors and actuators used in those systems are introduced below.

Interconnection of engine room harness
Interconnection of engine room harness, instrument harness and body harness

 

Laser sensors for low-speed collision avoidance assist brake and leading vehicle start alert

 When the vehicle is running at 4 to 30km/h and the system detects a potential risk of collision with another vehicle ahead, the system warns the driver audibly and visually. The system applies emergency brakes when the relative speed between the two vehicles is 20km/h or lower to avoid collision, and to mitigate damage of collision when the relative speed is 20 to 30km/h. The system works at relatively low speeds but is quite useful in preventing rear-end collisions caused by carelessness while driving in congestion. The system also alerts the driver when the vehicle ahead has started off, and prevents the driver from starting when there is an obstacle in front of the vehicle. The Move is fitted with Denso's sensors. Their photos are shown below.

 

Front bumper attachment Laser sensor
Front bumper attachment Laser sensor

 

Laser sensor interior Laser sensor interior
Laser sensor interior (Denso)

 

Vehicle Stability Control (VSC)

 When the car slips on a slippery road, the VSC prevents the car from spinning. When the driver applies panic braking, it supports the driver by automatically applying brakes to prevent locking the wheels so that the vehicle is steered safely. The system detects the vehicle's driving conditions and the driver's operations to control the engine torques or individual brakes to maintain vehicle stability. The system ECU is integrated with the hydraulic brake control actuator. It controls the low-speed collision avoidance assist brake as well. The engine ECU controls the engine torques according to the signals from the VSC system ECU. The vehicle's acceleration, deceleration and lateral gravity sensors and yaw rate sensors are assembled in a single sensor unit and installed at the center of the cabin. The front, rear and lateral gravity sensors and yaw rate sensors are supplied by Denso. The Move is also fitted with individual wheel speed sensors and steering angle sensors.

 

Built-in Hydraulic brake control actuator in ECU Front/rear/lateral gravity sensors and yaw rate sensors
Built-in Hydraulic brake control actuator in ECU Acceleration/deceleration/lateral gravity sensors and yaw rate sensors

 

Push-to-start keyless entry system

Keyless entry system ECU
Keyless entry system ECU

 The keyless entry system is a proximity entry system that allows unlocking and locking the vehicle door without using a conventional mechanical key. The driver can unlock and lock the door simply by pressing the door button without taking a key out from his or her pocket or bag. Similarly, the driver can start and stop the engine simply by pressing the ignition button, if the key is kept in the cabin. A total of five 125kHz signal transmitters are used in the Move. They are located in the right- and left-side door mirrors and a back mirror, and in the instrument panel and the luggage room. The system key receives signals and sends a 315MHz signal to the receiver located inside the ECU identifying the source of the received signal. In this way, the ECU can tell where the key is. The person having the key in the proximity of the vehicle can unlock and lock the door and start and stop the engine by operating the respective buttons. The system key of the Daihatsu Move is supplied by Tokai Rika.


 

Signal transmitter in the door mirror Signal transmitter in the rear bumper
Signal transmitter in the door mirror Signal transmitter in the rear bumper

 

Signal transmitter in the cabin Signal transmitter in the cabin
Signal transmitter in the cabin (instrument panel) Signal transmitter in the cabin (luggage room)

 

 



Vehicle specifications and list of equipment

Vehicle Model name Daihatsu Move X turbo VS (special version)+available Smart Selection SA
Price JPY 1.33million+JPY 60,000 for available Smart Selection SA
Body size Length: 3,395mm X Width: 1,475mm X Height: 1,620mm
Wheelbase 2,455mm
Tread Front 1,350mm / Rear1,295mm
Ground clearance 150mm
Curb weight 820kg
Seating capacity 4
Engine Type KF type inline 3-cylinder intercooler turbo
Intake and exhaust valve mechanism DOHC 12Valve
Displacement 658 cc
Bore X Stroke 63.0 mm X 70.4 mm
Compression ratio 9.0
Fuel supply method Electric fuel injection
Fuel Unleaded regular gasoline
Maximum output 47 kW / 6400 rpm
Maximum torque 92 Nm / 4200 rpm
Transmission Transmission Torque converter and CVT with lockup mechanism (in-house production)
Transmission gear ratio Forward 3.327 - 0.628
Final drive gear ratio 4.8
Fuel economy on JC08 mode 25.20 km/L
Chassis Front suspension MacPherson strut
Rear suspension Torsion beam
Steering Rack and Pinion
Front brakes Ventilated disc bakes
Rear brakes Leading/trailing drum brakes
Tire size 155 / 65R14 75S
Safety equipment Standard equipment Collision safety body TAF
dual (for both driver- and front passenger-side)SRS airbag
Front three-point ELR seatbelt with front pre-tensioner and force limiter
Rear three-point ELR seatbelt
ISOFIX-compliant child restraint anchorage system with top tether
Antilock brake system (ABS) with electronic brake force distribution (EBD)
Emergency stop signal
Reverse-linked rear window wiper
Available equipment for the VS version Smart Assist crash avoidance system
Low-speed collision avoidance assist brake
Unintended start prevention
Leading vehicle start alert
Vehicle Stability Control (VSC)
Traction Control (TRC)
Equipment for driving comfort Push-to-start keyless entry system
Keyless entry system
Automatic air conditioner
Automatic lighting
Power window with switch light on all doors and automatic-reversing function
Bench type seat with seat lifter for driver's seat
Split reclining rear seat integrated with sliding mechanism up to 240mm

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