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Three different types of front suspension and the corresponding body construction configurations were selected for comparison among unitary constructed sub-compact cars with a weight range between 2,500 lb and 3,000 lb and which are being manufactured by Toyota. These were compared and evaluated in terms of weight, productivity, noise and vibration characteristics, and crashworthiness. The pros and cons of each type were analyzed and the results of this analysis are presented in this paper. From these results, it has been concluded that when only the front body is considered, these three types of front body design are preferable in the following order. 1. McPherson type. 2. Double wishbone type with upper and lower arms installed on the fender apron. 3. Double wishbone type with upper and lower arms mounted on the suspension member.

Various types of belt systems with emergency locking retractors (ELR) have been developed and evaluated for their efficiency and comfort. The optimum belt system in combination with the starter interlock system is considered to be the three-point belt system with separate lap and shoulder electromagnetic ELR. We have developed a reliable and comfortable OFF-lock type retractor by incorporating a locking release mechanism that will operate when a predetermined length of belt is pulled out. This device is small enough to be embedded in the roof side structure of a vehicle by using narrower webbing (24 mm) and an electrical locking retractor which is smaller than the conventional mechanical type. The electromagnetic ELR system, combined with a mercury g sensor, was tested and evaluated for locking time, comfort, and injury criteria, as well the strength of the narrow webbing.

The basic elements of the Toyota ESV energy management system consist of silicone rubber-type front bumper shock absorbers, an efficient energy-absorbing frame, and upper members for preventing vehicle pitch during impact. The Toyota ESV proved to have satisfactory performance in an 80 km/h frontal impact against flat and pole barriers by adequately balancing the strengths of these elements and effectively arranging the energy-absorbing members of the frame. In addition, based on experiences with the ESV tests, the relationships between crashworthiness variations and vehicle weight or size were studied in detail.