Toyota Hybrid Presentation PDF

Course 071 Toyota Hybrid System
Welcome
071 Toyota Hybrid System 1

Course Agenda
Day One
Hybrid System Overview
Transaxle Operation
Day Two
High Voltage System
Engine
Day Three
Brake System
Electric Power Steering
Air Conditioning
Multiplex Communication
Hybrid General Maintenance

Worksheet Overview
Worksheet 1: Hybrid Walkarounds
Worksheet 2: Data List Test Drive
ILD 1: Transaxle Assembly Parts Identification

ILD 2: Inverter Safety
ILD 3: Battery Safety
Worksheet 3: High Voltage System

Worksheet 4: HV Battery State of Charge
ILD 4: Highlander Hybrid EPS on Pico Scope
Worksheet 5: Techstream (Hybrid EPS Initialization,

Electric Air Conditioning System)

Hybrid System
Overview

Toyota Hybrid Technology
Toyota has been

researching emission
reduction technology
since 1975.
Toyota is the
world leader in
hybrid technology.

This slide is hidden. It does not appear in the slide show. Its
purpose is to create an extra page for handbook text.

Toyota Hybrid System (THS)
01 03 Prius
1NZ-FXE Engine
HV Battery
Inverter
Hybrid Transaxle
Motor / Generator 1
Motor / Generator 2

Hybrid System Overview (THS II)
Highlander Hybrid
Inverter
Assembly HV Battery
Engine
Rear Drive Unit

- Motor Generator Rear (MGR)
(4WD-i Only)
HV Transaxle
- Motor Generator 1 (MG1)
Hybrid System Engines
Highlander Hybrid
01 03 Prius1NZ-FXE (1.5L)
04 09 Prius.1NZ-FXE (1.5L)
10 up Prius2ZR-FXE (1.8L)
Highlander HV3MZ-FE (3.3L)
Camry HV....2AZ-FXE (2.4L)

Hybrid Drivetrain Components
Highlander Hybrid
Hybrid Transaxle
- MG1
- MG2
Rear Drive Unit
- MGR (shown)
Rear Drive Unit

- Motor Generator Rear (MGR)
(4WD-i Only)
HV Transaxle
Highlander Hybrid
Inverter
Assembly
Inverter
Controls current to
motor generators
Also provides correct
voltages to other
systems.

Highlander Hybrid
HV Battery
HV Battery
Stores electrical
energy to drive
the system

Hybrid Vehicle Safety Precaution
2010 Prius
All hybrid system high-voltage wire harnesses are orange.

The HV battery and other high-voltage components have
High Voltage caution labels.
Do not carelessly touch these wires and components.

Hybrid System Control Modes

READY

Starting Out

Engine Starting

Light Acceleration

Light Load Cruise

Full Acceleration

Deceleration

Reverse

Energy Monitor & Fuel Consumption Display
Highlander Hybrid

Push Button Start
ACC IG-ON
OFF READY
Insert the key (non- Push the POWER

Vehicles enters
Smart Key equipped, switch with the brake
READY mode
04 09 Prius only) pedal depressed

Worksheet 1
Walkaround

Worksheet 2
Test Drive

Warning Lights
04 09 Prius
READY Light Malfunction Indicator Light
Low
temperature
indicator
light
Master Warning Light

[END Module 1 Overview]

Transaxle
Operation

Hybrid Transaxle
01 03 Prius
Silent Chain MG2
MG1
Transaxle Damper
Planetary Gear Unit

Construction of MG1
Rotor 01 03 Prius
Stator Coil
Resolver

Construction of MG2
01 03 Prius
Stator Coil Rotor
Resolver

Motor/Generators
2010 Prius
Total weight is reduced approximately 33%
MG2 maximum output is increased to 80 HP
Previous Model 2010 Prius PRIUS
More compact, more light

weight design achieved
MG1
through centralized winding of
the coils.
Motor rotational speed was

MG2 significantly increased,
improving power performance
P112 P410
Construction of MGR
Highlander Hybrid
Resolver Stator Rotor

Speed Sensor (Resolver) Operation
Detects magnetic pole position

HV ECU uses the Resolver as a
speed sensor and calculates
position variations
Magnetized
Stator Side
Coil A
Coil B
Output
Rotor Side
Coil C

Permanent Magnet Motor Generator

P410 Hybrid Transaxle
2010 Prius
Compound Gear Unit

Power Split Planetary
MG2
Gear (Right Side)
Motor Speed Reduction
Planetary Gear
(Left Side)
Oil Pump
(Mechanical) Transaxle Damper
MG1
Final Drive Gear
Final Driven Gear
Counter Driven Gear
Differential Gear Unit

Compound Gear Unit - Components
2010 Prius
Compound Gear Unit
Motor Speed
Reduction Planetary
Gear Unit
Power Split
Planetary Gear Unit
Counter Drive Gear

(Compound Gear)

Compound Gear Unit - Operation
Highlander Hybrid
Carrier
MG2 MG1
Engine
Ring Gear Carrier
Counter
Driven Gear
(To Wheels)

Transaxle Damper
2010 Prius
A coil & torque limiter provide damping

Torque limiter
Coil spring
Transaxle Damper

P112 Hybrid Transaxle Service
04 09 Prius
Filler Plug
(for ATF)
Adopts a shift
control actuator Oil pan is
discontinued & WS
type ATF is used
Drain Plug Drain Plug

(for Coolant) (for ATF)

2010 Prius
Filler Plug for Hybrid

Transaxle Fluid
Fluid Type WS
Capacity 3.5 qts
Maintenance Interval 100,000 miles

(initial)

(subsequent)
Drain Plug for Hybrid Drain Plug for Hybrid

Transaxle Fluid System Coolant

Camry Hybrid
WS Fluid Fill Plug
(10mm hex)
0 to 0.20
in.
WS Fluid Drain Plug Hybrid System Coolant

(10mm hex) Drain Plug
(10mm hex)

Shift Control P111
01 03 Prius
Shift Position Sensor
HV
ECU Engine
ECU
(ECM)
BEAN
Combination
Meter

Shift Assembly P112
04 09 Prius
Select Sensor
Shift Sensor

Shift Control Actuator P112
04 09 Prius
Cycloid Reduction
Mechanism
Stator &
Coil
Shift Control Actuator
Rotor
Rotation Angle
Sensor

Parking Lock Mechanism P112
04 09 Prius
Hybrid Transaxle
Parking Switch
Shift Control
Actuator Parking Lock
Mechanism
Request Control
T/M
HV ECU Control
ECU
P or Not P Position
Shift Lever

Service Tip
04 09 Prius
If you cannot shut the hybrid system OFF, there may

be a malfunction in the shift control actuator that is
preventing the vehicle from going into park.
To solve this and apply

problem, stop the the parking
vehicle brake.
This will bypass the problem, allowing the vehicle to shut down.

Drive Modes
ECO MODE 2010 Prius
Moderates the response to accelerator pedal
PWR MODE
operation to optimize fuel economy Optimizes acceleration performance
Moderates the A/C performance to optimize by increasing the motive force in
fuel economy relation to accelerator pedal operation
Normal
EV Mode
Motive Force Output

Driving with only the electric motor
PWR
Mode
ECO
Mode
Accelerator Pedal Opening Angle


Service Tip - P311
Camry Hybrid
Transaxle Control Cable Adjustment
1 Shift to N range
4
Lock Piece Slider
2
5
3 Shift Cable

Instructor Led Demo
Transaxle Assembly &

Parts Identification

[END Module 2 Transaxle Operation]

High Voltage
System

Certified Hybrid Vehicle Technician
CAUTION
This module does not certify you to work on hybrid vehicle high-voltage systems.
The Certified Technician must complete course 071 Toyota Hybrid System to
safely begin working on Toyota hybrid vehicles.
Until you complete course 071:

Never touch, disassemble, remove or replace the high-voltage parts, cables and
their connectors. (High-voltage parts and cables are colored orange or have high-
voltage warning labels.)
Do not try to access the service plug.
Failure to comply with these warning can cause severe burns or electric shock that
may result in death or serious injury.

Hybrid Vehicle Safety

Power Cable Routing Prius
01 10 Prius
Inverter HV Battery
A/C Compressor Auxiliary

Battery
Engine Room Auxiliary

Junction Block Battery
Inverter
Engine Room HV Battery
Junction Block
2001-2003 Prius 2004-2009 Prius
A/C Compressor Junction Block
HV Battery
Inverter
2010-up Prius

Power Cable Routing Other Models
Power Steering Converter
A/C Compressor HV Relay Assembly
Rear Drive
Unit (MGR)
Inverter Battery Smart Unit &

Assembly HV Battery HV Relay Assembly
Highlander Hybrid A/C Compressor
Inverter
Assembly HV Battery
Camry Hybrid
DC-DC Converter

HV Battery

Nickel-Metal Hydride Battery
04 09 Prius
The Nickel-Metal Hydride
(Ni-MH) hybrid vehicle (HV)
battery stores electrical
energy to drive the system.
Nominal battery voltages:
01-03 Prius 04 & later Prius Highlander Hybrid Camry Hybrid

274 VDC 202 VDC 288 VDC 245 VDC

HV Battery - Layout
01 03 Prius
Battery Pack Upper Case
Battery ECU
SMR (System Main Relay)
HV Battery Module

HV Battery - Layout
04 09 Prius
HV Battery
Front Bus Bar Module
Module
SMR 3 Rear Bus Bar

Module
SMR 2
Battery ECU
SMR 1

HV Battery - Components
2010 Prius
Temperature Sensors
(for battery modules)
HV Battery
(Battery Modules) Battery Smart
Unit
HV Battery
Cooling Blower
HV Junction
Block Assembly
HV Battery
Temperature Sensor
(for intake air)
CAUTION: The HV battery is a high-voltage component that only Certified Hybrid Technicians
should service.
HV Battery State of Charge (SOC)
Example of change in SOC Upper SOC

control limit
Overcharged region
Control
region
SOC
Undercharged region
Time
Lower SOC
control limit Target SOC control

System Main Relays (SMR)
2010 Prius
Battery SMRG SMRB Power Management

Smart Unit Control ECU (HV CPU)
HV Battery
Current Senor
SMRB
Service
Battery Modules
Plug
Resistor
SMRP
SMRG
HV Battery SMRP Precharge
Current Sensor Resistor
Note: Do NOT remove SMRs on the HV junction block assembly.

SMR Control
SMR2
(+) to Inverter
Resistor
SMR1
Service Plug
High-
Voltage
Fuse
SMR3
(-) to Inverter
GND to THS ECU

Prius HV Battery Cooling
2001-2003
Prius 2004-2009 2010-up
Prius Prius

HV Battery Cooling
2007-2010
Camry Hybrid
2006-2007
Highlander Hybrid

Inverter

Inverter Assembly
Highlander Hybrid
HSD Inverter
MG ECU
Controls inverter
components
Boost Converter
288 VDC - 650 VDC
Inverter
AC - DC
DC-DC Converter
288 VDC - 12 VDC

Toyota Hybrid System Charger
Front
Back

Safety Steps

Hybrid Service Safety Precautions
See the Repair Manual for vehicle-specific details.

Preparation

Service Tip - HV Battery
Precautions before working on hybrid system

If DTC P0AA6 or P3009 are set, troubleshoot the DTC 1st.
DTC Detailed Information

Code Display INF Code Information (Trouble Area)
P0AA6 Hybrid Battery 526 Insulation abnormality of the entire
Voltage high-voltage circuit
System 611 Electric Compressor & A/C Inverter
Isolation Fault
612 HV Battery, Battery Smart Unit, HV
Relay Assembly
613 Hybrid Transmission, Inverter with
Converter Assembly
614 DC High-voltage Area

READY OFF & Securing Smart Key
Service Should be performed with READY OFF & key removed
from ignition.
Secure the smart key at least 10 feet away from the vehicle to
provide additional safety.
Disconnect the cable from auxiliary battery negative terminal.
Approx. 10 ft. radius

(not to scale)

Personal Protective Equipment (PPE)
Electrical insulating
gloves must be worn
when working with
Hybrid components.
Class 0 gloves offer

adequate protection for
Toyota Hybrid vehicles.
Maximum Use Voltage AC

Class Max. Use Voltage AC Class Max. Use Voltage AC
Low Voltage High Voltage
00 500 1 7,500
0 1,000 2 17,000
3 26,500
4 36,000

PPE - Glove Protectors and Liners
Protector gloves may be omitted for

Class 0 Gloves, under limited use
conditions, where small equipment and
parts manipulation require unusually
good finger dexterity.
Clean, dry cloth gloves may be worn

inside of insulating gloves for warmth in
cold weather or to absorb perspiration
in hot weather.

PPE Certification & Replacement
Gloves that have been in-service for six months must either:
1.Be sent out for electrical testing or
2.Disposed of and replaced with new Gloves.


Insulated Glove Procedures
IMPORTANT: DO NOT USE GLOVES IF;

THEY ARE WET OR DAMP.
IT IS AFTER THE TESTING DUE DATE MARKED ON THE
CUFFS (OR MORE THAN 6 MONTHS FROM DATE OF ISSUE).
Steps to be taken by the wearer, EVERY TIME, BEFORE putting

the Gloves on:
Remove all rings and bracelets to avoid any damage to the
Gloves.
Wash hands with a mild soap & dry hands thoroughly before
putting on the Gloves.

Insulated Glove Care & Storage
Note: Exposure to chemicals, solvents, ozone, aging & extreme

temperatures can degrade gloves.
Follow the instructions for the care, decontamination &
maintenance provided by the glove manufacturer or supplier.
Good housekeeping can help extend glove life.
Also, keep your work area clean from contaminants.
Gloves must be stored in their natural shape & protected from
physical damage.
Gloves should be stored in cool, dark & dry location.
Gloves may be kept inside of a bag, box, or container
designed for & used exclusively for them.

Insulated Glove Inspection
Before use, check the insulated gloves for cracks, tears and other
types of damage by performing the following procedure.
1. Place the glove on its side

2. Roll the opening up 2 or 3 times
3. Fold the opening in half to close it
4. Confirm that there are no air leaks


Caution Notification & Managing Safety
Use the provided sign stating:
CAUTION: HIGH VOLTAGE.

DO NOT TOUCH DURING OPERATION
Best Practices include:

Confirming that the work area is dry.
Confirming that the areas around the hybrid components
(HV battery, inverter) are dry.
Creating and maintaining a safe zone around hybrid vehicle
as appropriate.

Testing High Voltage
Use
Underwriters
Laboratories
approved CAT III
(1000V) test
equipment.

Service Plug
Removal

Service Plugs
3
3 Steps to remove Large type Service Plug
2 1
Rear Door Scuff Plate LH Protective Cover
2 Steps to remove Small type Service Plug

Secure Service Plug
Keep the removed service plug in a

secure location to prevent accidental
reconnection while you are working on
the high-voltage components.

Hybrid Vehicle Inverter Precautions
Time discharges the capacitors.
High-voltage Condensers
Dis
cha
rge
0V
Electricity
Service plug removal MODEL Discharge

Time WAIT TIME from Service
Plug Removal
2001-2009 Prius 5 minutes
2010-up Prius 10 minutes

Highlander Hybrid 5 minutes
Camry Hybrid 10 minutes

Instructor Led Demo
Inverter Assembly &

Parts Identification

During HV Repair

Hybrid Service Safety Precautions
Best Practices
Prevent conductive objects from completing the circuit between
energized conductors.
Do not use a universal joint. It can rotate accidentally &
complete a circuit.
Leaving the battery case open without the cover may expose
others to high voltage hazard. Never leave the HV battery
unattended with the cover off.

Insulating Connectors
CAUTION:
Do not touch any bare cables that may have high-voltage.
Cover disconnected high-voltage connectors with insulating
vinyl tape
Insulated Vinyl Tape

Chemical Hazards
Highlander Hybrid
If electrolyte is present at the bottom of the battery case,

avoid contact with the fluid.
Dont touch!

HV Battery Recycling Overview
All hybrid vehicle HV batteries are recyclable see Warranty Parts

Recovery Program for details.

Proceed with Repair
New Nut Old Nut
Some inverter nuts and

bolts cannot be reused.
See RM for inverter
installation details.

HV Battery Post Cleaning
On some early models the battery

posts may show signs of corrosion.
This issue was addressed by Special
Service Campaign 40G.

Instructor Led Demo
04 09 Prius HV
Battery, 10 Prius HV
Battery, Camry HV
Battery, Highlander HV
Battery Assembly & Parts
Identification

After HV Repair

Hybrid Vehicle Repair Quality Checks
After Potential
Repair Damage
START
Installation
Hydrogen
Vent Hose

Service Plug Installation After Repair
Small Service Plug Installation: Large Service Plug Installation:
2
2
Click is
heard

Precautions for DC-DC Converter
2010 Prius

Worksheet 3 & 4
HV Systems
State of Charge (SOC)

[END Module 3 High Voltage System]

Engine
10 & later Prius: 2ZR-FXE
01 09 Prius: 1NZ-FXE
Highlander Hybrid: 3MZ-FE
Camry Hybrid: 2AZ-FXE

Horsepower Calculations
04 09 Prius
Highlander Hybrid Prius Gen 2

V6 Engine: 208 HP 1.5L Engine: 76 HP
Front Drive Motor: 165 HP Front Drive Motor: 68 HP
Rear Drive Motor: 67 HP HV Battery: + 34 HP
HV Battery: + 60 HP Actual HP 110 HP
Actual HP 268 HP
Camry Hybrid Prius Gen 3

Engine: 147 HP 1.8L Engine: 98 HP
Front Drive Motor: 143 HP Front Drive Motor: 80 HP
HV Battery: +45 HP HV Battery: + 35 HP
Actual HP 134 HP
Actual HP 192 HP

2010 & Later Prius
2ZR-FXE

2ZR-FXE Engine
04 10 Prius
04-09 MY 10 & later
Engine 1NZ-FXE 2ZR-FXE

Displacement (liters) 1.5 1.8
Engine Oil Capacity dry (qts) 4.3 5.0
Engine Oil Capacity w/ filters (qts) 3.9 4.4
Compression Ratio 13.0:1 13.0:1
Horsepower 76 @ 5000 98 @ 5200
Torque (ft. lbf) 85 @ 4200 105 @ 4000
Maximum System Output (hp) 109 134
Maximum Voltage 500 650
Emission Regulation AT-PZEV AT-PZEV
Note that if the 5th character in the engine designation is an X,

that engine is considered an Atkinson type.

Exhaust Gas Recirculation System (EGR)
2010 Prius
EGR Valve Coil
Valve
To Intake
Manifold
EGR Cooler
From EGR Cooler

EGR Gas
Silicon Chip Cross Section

Engine Coolant
MAP Sensor
(Vacuum Sensor)


Electric Water Pump
2010 Prius
Electric Water Pump

Stator
Rotor
Shaft
Motor
Electric Water Pump

No accessory belt
New Active Test and
Data List items
New DTCs for pump

Cooling System Components
2010 Prius
Reservoir Tank Coolant Temperature Sensor

EGR Valve
Air Release Valve
From Heater Core
To Heater Core
From Exhaust Pipe Gas

Control Actuator
Electric Water
Pump
EGR Cooler To Exhaust Pipe Gas
Throttle Body
Control Actuator
From Radiator
To Radiator

Exhaust Heat Recirculation System
Coolant Temperature Switch 2010 Prius
Engine Engine
Coolant Combination Meter
Exhaust Gas
Exhaust Pipe Gas Valve

Control Actuator
Rod
Valve is closed Valve is open

(Coolant Cold) (Coolant Warmed Up)

Exhaust Heat Recirculation Parts
2010 Prius
Exhaust Pipe Gas

Control Actuator Case
Exhaust Pipe Gas

Control Actuator
Gasket
Exhaust Pipe Gas
Control Stopper

Engine Coolant Change
2010 Prius
Air Release Valve
Cylinder Block
Reservoir Drain Cock Plug Service Tip - follow
Tank Cap Repair Manual
procedures carefully &
use the air release
valve to remove all air
from the system.
Air Release
Valve
Coolant Type SLLC
Capacity 7.7 qts

Radiator Drain
Maintenance Interval 100,000 miles Cock Plug
(initial)
(subsequent)

Service Tips (Engine Coolant Change)
2010 Prius
B Line
Use the air release valve to remove air from

the system.
Add SLLC to B line of reservoir tank.
Squeeze inlet & outlet hoses & then check
coolant level.
Run engine in inspection mode to warm it up. After the
thermostat is open, allow coolant to circulate for
several minutes (approximately 7 minutes).
FULL
After the engine has cooled, check that LOW
coolant level is between FULL & LOW

04 09 Prius
1NZ-FXE

Coolant Heat Storage System
04 09 Prius
Engine Coolant Temp. Sensor to heater core
(for engine control system)
Water Pump
(for heater)
Coolant Flow Reverse View

Control Valve
Coolant Heat
Storage Tank
Engine Coolant Temp. Sensor Water Pump

(for coolant heat storage system) (for coolant heat
storage system)

Coolant Heat Storage Tank
04 09 Prius
Bleeding air Drain Plug

from the
system is
critical
Pump
to/from
Water Valve
Outlet Temp. Sensor

Prius Coolant Heat Storage Operation
04 09 Prius
2.5 V (VLV3)
4.5 V (VLV5)
3.5 V (VLV4)
2.5 V

THS-II Engine Coolant Change
04 09 Prius
Specifications
Fluid Toyota Super Long Life

Coolant (SLLC)
Capacity 9.1 qt (8.6 L)
Service Tip: Refer to the Repair Manual for details.

01 03 Prius
1NZ-FXE

Intake Manifold - 1NZ-FXE
01 09 Prius
Intake Pipes
Throttle Control
Motor
Throttle Position
Sensor
Surge Tank

HC Adsorber and Catalyst (HCAC)
01 03 Prius
TWC
Actuator
HC Adsorber
TWC with
HC Adsorber
Main Muffler
Bypass Valve Closed

TWC
VIEW HC ADSORPTION CATALYST SYSTEM

THS Engine Coolant Change
Bleeder Point
Engine Coolant Fill

Specifications
Fluid Toyota Super Long Life
Coolant (SLLC)
Capacity 5.2 qt (4.9 L)

Service Tip: Refer to the Repair Manual for details

Highlander Hybrid 3MZ-FE
Camry Hybrid 2AZ-FXE

Highlander Hybrid Engine Coolant Change
2006 - 2007 Highlander Hybrid 2008 - 2010 Highlander Hybrid
Radiator Drain Cock Plug Radiator Drain Cock Plug
(Equipped with Vent Plug) Radiator Cap (Equipped with Vent Plug) Radiator Cap
Cylinder Block
Drain Cock Plug
Radiator Drain Cock Plug Radiator Drain Cock Plug

Cylinder Block Drain Cock Plug
Specifications
Fluid Toyota Super Long Life Coolant (SLLC)
Capacity 13.5 qt. with rear heater

11.2 qt. without rear heater
Service Tip: Refer to the Repair Manual for details

Camry Hybrid Engine Coolant Change
Radiator Cap
Cylinder Block Drain

Cock Plug
Radiator Drain
Cock Plug
Specifications
Fluid Toyota Super Long Life Coolant (SLLC)
Capacity 6.6 qt.
Service Tip: Refer to the Repair Manual for details.

EVAP
01 09 Prius: 1NZ-FXE

Bladder Fuel Tank
01 03 Prius
Resin Bladder
Fuel Sender
Mounting
Sub Tank
Steel Tank
Interior

Fuel Sender Gauge
01 03 Prius
Reed
Switch
Body Meter
Display
ECU ECU
Float
Combination Meter
Fuel Sender
Gauge

Inclination Sensors
Combination Meter Combination Meter
Meter Sender Meter

ECU Gauge ECU
Signal
Body
ECU
Inclination InclinationAmbient
Ambient
Sensors Temp. Sensors Sensor
Temp
Sensor
Fuel Fuel
Sender Sender
Main Tank Gauge Main Tank Gauge
01 03 Prius 04 09 Prius

EVAP Control Components
Fresh Air
Line
VSV (for Canister

Closed Valve)

EVAP Control Components
04 09 Prius
Throttle Valve
Air Cleaner
ORVR REFUELING ECM

PURGING
VSV (for Purge Flow
VSV (for EVAP) Switching Valve)
Refuel Check Charcoal

Valve Canister
Fresh Air Vapor Pressure EVAP Line

Trap Filter
Line Sensor
Filler Pipe
VSV (for Canister

Closed Valve)
Fuel Tank

EVAP
Highlander Hybrid:
3MZ-FE

Closed Fuel Tank System
Highlander Hybrid
Fuel Outlet Valve Fuel Vapor

THS (Closed) Containment Valve
ECU
Canister
Pump Module

Refueling Procedure
Highlander Hybrid

EVAP
10 & Later Prius:
2ZR-FXE

Fuel System
2010 Prius
Bladderless, layered
plastic fuel tank
Key Off EVAP System
Fuel Delivery
Pipe
12-hole Type
Fuel Injector
Fuel Pump Assembly

- Fuel Filter
- Pressure Regulator
- Fuel Sender Gauge
Quick Connector

Fuel System Key OFF EVAP
2010 Prius
Fuel Cut-off Valve
Vent Line
Fuel Filler Check Valve
Purge Purge Line

VSV
Fuel Tank
[Pump Module]
Air Inlet Vent

Air Filter Valve
Line
Leak Detection Pump
ECM
Canister Pressure Sensor Charcoal
Canister
* The purge VSV control has changed and the purge flow volume
increased.
Diagnostic Inspection Modes
FWD Inspection Mode

within 60 seconds
Accelerator
Pedal IG-ON
OFF
READY
IG-ON ON
(but not Depress Depress Depress

READY ON) 2 times 2 times 2 times
Change to IG OFF inspection mode is canceled

[END Module 4 Engine]

Brake System

Electronically Controlled Brakes (ECB)
Power Management Control ECU
Main Body ECU
Brake Pedal
Stroke Sensor
Brake Master Cylinder

Reservoir
Steering Angle
Sensor
Yaw Rate and

Acceleration Sensor
Brake Booster with Master Cylinder
Pump Assembly Wheel Speed Sensor

w/ Accumulator

Prius ECB Layout
2004 to 2009:
2010-up: Electronic Brake Actuator
Hydraulic Brake Booster 20012003: with Stroke Simulator
with Stroke Simulator Hydraulic Boosted
Master Cylinder

Brake System Comparison
01 03 Prius 04 09 Prius 10 & later Prius Highlander Camry Hybrid

Hybrid
Regenerative Brake Cooperative Control
ABS w/ EBD
Hydraulic Electronically Controlled Braking (ECB)
Brake
Booster*
- Brake Assist
- ** TRAC
- - HAC -
- Enhanced VSC VSC
- - - VDIM
* Three channel ECB

** Motor Traction Control function of HV ECU provides a similar function

Brake Control System - Apportioning of Force
2010 Prius
Hydraulic & regenerative force
Drivers Demand
Braking Hydraulic
Force Braking Force
Regenerative
Braking Force
Time
Changes in Braking Force Apportionment

Electronically Controlled Braking System
Brake Pedal Stroke Sensor : Electrical Signal Highlander Hybrid
: Fluid Pressure
Master Cylinder
Pressure Sensor
EPS
Skid Control ECU
THS-II
Regenerative
Hydraulic Power Hydraulic Control Brake Force
Source Portion Portion
Hydraulic Brake Force
Brake Force

Brake Pedal Stroke Sensor
04 09 Prius
Brake Pedal Stroke

Sensor
Stop Light Switch
Sensor Lever
SKS2
Voltage
SKS1
1
Brake Pedal
0
-15 0 60
Sensor Lever Rotational Angle

Accumulator/
Actuator

Master Cylinder
Brake Booster with Master

Cylinder
Brake Actuator
Skid Control ECU
2 Linear Solenoid Valves
4 Switching Solenoid Valves
8 Control Solenoid Valves
Pressure sensors for:
- Regulator
- Wheel Cylinder
Stroke - Accumulator
Simulator
Brake Actuator

Brake Hydraulic Circuit
Accumulator 2010 Prius
Pump Motor
Fluid Level
Hydraulic Brake Booster
Warning
Switch
: Accumulator
Pressure Sensor
Stroke : Regulator Pressure Sensor

Simulator
: Wheel Pressure Sensor
Brake Actuator
: Linear Solenoid Valve
: Switching Solenoid Valve
: Pressure Holding
Solenoid Valve
: Pressure Reduction
Solenoid Valve
FR LH FR RH RR LH RR RH

Warning Lights

Brake Control System - Combination Meter
2010 Prius
Warning light illumination
Brake Brake ABS Warning VSC Slip

Warning Light Warning Warning Light Indicator
Light / Yellow Light / Red
Conditions
TRAC (TRC), VSC or HAC operation - - - Illuminate

Malfunction in ABS, EBD or BA - - Illuminate -
Malfunction in TRAC (TRC) or VSC - - Blink
Malfunction in the apportioning of brake - Illuminate - -

Parking brake ON or low brake fluid level - Illuminate - -
System malfunction not affecting brake force Illuminate - -
Shown above is the 2010 Prius. Other Models are similar.

Service Details

ECB Utilities

Service Tip - Brake Fluid Level
2010 Prius
Adjust the fluid level in the reservoir between MIN line

& Fluid Level Support Line.
MAX Line
Fluid Level
Support Line
MIN Line

Backup Control Power Source
Highlander Hybrid
Capacitor Cell

[END Module 5 Brakes]

Electric Power
Steering

Electric Power Steering (EPS)
Provides power assist even

when engine is not running.
Improves fuel economy.
Consumes energy only
when assist is required.

Electric Power Steering Components
EPS
DC motor
ECU
Torque sensor Torque sensor
DC motor
20012003 Prius Camry Hybrid and

20062007 Highlander Hybrid
EPS
ECU
DC motor
Torque sensor
2004 and later Prius

2008 and later Highlander Hybrid

EPS - Torque Sensor
Torque Sensor DC Motor
Detection Coil Correction

Coil
Torsion
Bar
Detection Detection
Ring 3 Detection Ring 1
Ring 2
04 09 Prius
01 03 Prius
Torque Sensor Video Torque Sensor Animation

EPS Steering System Diagram
04 09 Prius
Gateway ECU
Skid Control ECU Meter ECU

Multi Display
Vehicle Speed Master Warning
signal Light
Assist torque
Warning display
EPS Warning
demand signal (for Display Request
Enhanced VSC*)
Signal to Multi
Display
Torque Sensor EPS ECU
HV ECU
READY signal
DLC3
DC Motor

Steering System Diagram
2010 Prius
Steering Column Assembly
Torque Sensor Power

Steering ECU
Rotation Angle Sensor*
Boost
Power Steering Motor Converter*
Models with
*
brushless type motor
V Bus No.1
DLC3 Steering Combination Skid Control Power

Angle Meter ECU Management
Sensor Vehicle Control ECU
Speed Signal

Brushless & Brush Type EPS
2010 Prius
Power
Power
Steering ECU
Steering ECU

- Brushless-type Power
Steering Motor
- Torque Sensor
- Rotation Angle Sensor

- Brush-type Power Steering
Motor
- Torque Sensor
Service Tip: The rotation angle sensor
automatically initializes when the vehicle is
driven at 22+ mph for 5 seconds with a low
yaw rate (straight ahead driving).

Steering - Difference from Previous Model
04 10 Prius
Item 2010 & Later Prius 04 09 Prius
Assist Location Type Column
Power Steering ECU Details N.A. W/Temperature Sensor1
Voltage Boost Control*, 2 N.A.
Motor Details DC Motor
Brush type (15-inch wheels) Brush type

or Brushless 3-phase Motor*, 2
Rotation Angle Sensor Resolver Type* N.A.
Torque Sensor Hall IC Type Inductance Type
Reduction Mechanism Worm & Wheel Gear
: Models with brushless type power steering motor only (17inch wheels)
*

Service Tip EPS Initialization
2010 Prius
Perform initialization & calibration on 2010 Prius EPS as follows:

Repair Motor Type Rotation Angle Torque Assist Map
Sensor Sensor Zero Writing
Initialization Point
Calibration
ECU replacement Brush O O
Column assy.
replacement
Left or right effort
differs Brushless O O O

Service Tip Spiral Cable
2010 Prius
Spiral Cable w/Steering Angle Sensor is a complete assembly
Combination
Switch Assembly
Spiral Cable with

Steering Angle Sensor
Do not remove the steering angle sensor from the Steering Angle
spiral cable Sensor
Do not replace or rotate the spiral cable with the
battery connected & engine switch ON
Tip: Ensure that the steering wheel is installed & aligned

straight when inspecting the steering sensor.
Spiral Cable

EPS Components
Highlander Hybrid
Combination Meter
EPS ECU
P/S Warning Light
THS ECU
DC - DC Converter (for EPS)
Skid Control ECU

Steering Gear Unit

EPS Steering System
CAN Highlander Hybrid
Gateway ECU
BEAN (Instrument Panel Bus)

Skid Control ECU Meter ECU
Vehicle Speed
signal P/S Warning
Assist torque Light
EPS ECU demand signal
THS ECU
READY signal
DLC 3 Voltage: 288 volts

Temperature
Sensor
DC-DC Converter
(for EPS) HV Battery
Torque Sensor
Motor Voltage: 42 volts
Rotation Angle Sensor

2006-2007 Highlander Hybrid - Power Steering Precaution
06 07 Highlander Hybrid
The orange harness leading to

the EPS DC-DC converter
carries 288 VDC.
The yellow power steering

wire harnesses carry 42 volts.

Instructor Led Demo
Highlander EPS

[END Module 6 EPS]

Air Conditioning

Air Conditioning Compressor
01 03 Prius
Selecting MAX A/C on

the 01-03 Prius will
cause the engine to run
continuously.

PTC Heater
PTC
Heaters
Aluminum
PTC
Fin Brass
Element
Plate
Electrode
PTC Insulation
Element Film
01 03 Prius 07 & later Camry Hybrid

Electric Coolant Pump
Provides stable heater performance even with engine stopped

To
Heater
From
Engine
04 09 Prius
From To
Bypass Valve Close Engine Heater
01 03 Prius Highlander Hybrid

Main Air Conditioning Components
04 09 Prius
Solar Sensor
A/C Inverter
A/C Water Pump
A/C ECU
Electric Room Temp. &
Compressor Humidity Sensor
Evap.
Temp. Clean Air Filter
Sensor
Blower Fan
Heater Core PTC Heater

PRECAUTION - Air Conditioning Compressor
Camry Hybrid
Handle electrical supply (orange cable) to Compressor from the

Inverter with care as high voltage may be present.
The Air Conditioning Compressor has a dedicated inverter to
convert DC Battery Voltage to AC.
ES27 compressor

Electric Compressor Construction
04 & later Prius & Highlander Hybrid
Oil Separator
A/C Inverter
Motor
Shaft
Fixed Scroll
Discharge Port
Variable Scroll
Brushless Motor
ES18 compressor ES27 compressor

ES14 Compressor Construction
2010 Prius
A/C Inverter
Scroll Type
(DC AC)
Compressor
DC 201.6 V
Oil
Separator
Brushless
Motor
Caution: Use only ND11 type compressor oil.

Solar Ventilation System & Remote Air Conditioning
2010 Prius
Solar Ventilation System can operate indefinitely
as long as the operating conditions are met
regardless of ambient air temperature.
Remote Air Conditioning System will operate for
approximately 3 minutes.
Solar Ventilation System Remote Air Conditioning System

Solar Ventilation System Components
2010 Prius
Moonroof Solar
lls
Module 6 Ce 6C
ell
Air Inlet Control s
Servo Motor Blower
Motor
Air Outlet Control
Servo Motor
Blower Motor Relay
Ventilation
Switch Solar Ventilation ECU
A/C Amplifier

Precaution: Solar Ventilation System
2010 Prius
CAUTION: Performing repairs with the solar ventilation

switch ON may cause the blower motor to operate
unexpectedly, resulting in various hazards.
Tips:
Turn the solar ventilation switch
OFF when servicing.
Cover the entire solar panel to
block sunlight.

Remote Air Conditioning
2010 Prius
Cools the cabin before entering vehicle.
Use A/C switch on the remote to activate.
Press
A/C System & Hold

PRECAUTION: Remote Air Conditioning
2010 Prius
When activated, IG relays are turned ON.
Turn the wiper switch & headlight dimmer switch OFF.
Store the key securely so that no one cannot operate the
remote A/C switch.
Power
HV Battery

PlasmaclusterTM Generator
Plasmacluster
Generator
- +
+
-
-
+
+ - +
-
Positive and
Negative Ions
2010 Prius
Camry Hybrid
Ejector Cycle System (ECS)
2010 Prius
Capillary Ejector
Tube
Condenser
Compressor
Expansion A A Cross Section
Valve
Top Tank
ECS Evaporator
Ejector Upwind Side A Evaporator

(Downwind Side)
A
Downwind Side
Capillary Tube Evaporator

(Upwind Side) Bottom
Tank

Ejector Cycle System (ECS)
2010 Prius
Ejector To Evaporator
(Upwind Side)
Nozzle
From Expansion
Valve
Mixing
Vacuum Portion
Diffuser
Portion
From Evaporator
(Downwind Side)

Cabin Air Filter Maintenance
2010 Prius
Vehicles with Solar Ventilation System
require more frequent cabin air filter
maintenance as follows:
Procedure Without Solar Ventilation With Solar Ventilation
Clean Every 15,000 miles Every 10,000 Miles
Replace Every 30,000 miles Every 20,000 Miles

Worksheet 5
EPS, A/C, Brakes,

Active Tests

[END Module 7 Air Conditioning]

Body Electrical
& Multiplex
Communication

Power Distributor Contents
Highlander Hybrid
Contact Semiconductor
Relays Fuses Relays
Front
Power
Distributor
Mode Monitor
Terminal

Automatic Headlight Beam Level
04 09 Prius
Service Tip - Initialize system after repair

Combination Meter
Vehicle Speed Signal
Headlight Beam
Level Control
Master Warning Light
ECU
Headlight Leveling
Actuator
Rear Height
Control Sensor (LH)

Automatic Headlight Beam Level
04 09 Prius
Service Tip - Initialization
Initialize this system when you reinstall or replace the

following items:
Reinstall Height Control Sensor

Suspension System
Replace Height Control Sensor

Suspension System
Headlight Beam Level Control ECU

Main Body ECU
2010 Prius
Main Body ECU
J/B
Junction Block

Painted Wire Harness
Painted only near Color (Color Code)

the connector
Front Door Black (B)
Wire Harness Red (R)
Blue (L)
Green (G)
Yellow (Y)
Brown (BR)
Violet (V)
White-Black (W-B)
Light Green (LG)
Pink (P)
Sky Blue (SB)

[END Module 8 Multiplex]

General Maintenance

Hybrid Vehicle Service Specifications
01 03 Prius 04 09 Prius 10 & later Highlander Camry

Prius
Fuel Octane Rating 87 (1) 87 (1) 87 87 or Higher 87 or Higher
Engine Oil 5W-30 (2,3) 5W-30 (2, 3) 0W-20 (6) 5W-30 5W-20(6)
(06-07)
0W-20 0W-20
(08-09)
Coolant LLC4) SLLC SLLC SLLC SLLC
Transaxle Fluid ATF T-IV WS ATF WS ATF WS ATF WS ATF
Compressor Oil ND8 ND11 (5) ND11 (5) ND11 (5) ND11 (5)
Notes:
1. Using a higher octane fuel may prevent normal engine operation.
2. Using a different oil viscosity (such as 10W-30) can cause oil to splash up into the intake manifold.
3. 2001 model specifies API Service SJ. 2002 and newer models specify API Service SL
4. SLLC can be used, however it does not extend the drain interval.
5. ND11 has electrical insulating properties & is the only compressor oil to be used.
6. SAE 5W-20 may be used. 0W-20 is the best choice for good fuel efficiency and good starting in cold weather.

Lubrication System
2010 Prius
A replaceable element oil filter is used
Filter P/N 04152-37010 includes O-ring
Pan gasket P/N is 90430-12031
Use ILSAC multi-grade engine oil 0W-20
Element Note: Do not remove the oil filter

bracket clip when removing the oil
O-ring filter cap assembly.
Oil Filter Cap


Prius - Tire & Wheel
2001-2003: P175/65R14 84S*
2004-2009: P185/65R15 86S

P195/55R16 86V**
2010 & later: P195/65R15 89S
P215/45R17 87S**
Tire Pressure: Front - 35 psi (17=33psi)
Rear - 33 psi (17=32psi)
* Extra load carrying capacity (XL) must be used

** option
01 03 Prius

Auxiliary Battery
TIP:
Take care not to damage temperature sensor during service.
Refer to Repair Manual for systems that must be initialized with a
battery disconnect.
Lead-calcium Alloy

Service - Auxiliary Battery
2010 Prius
Do NOT perform a quick charge.
Replace with dedicated battery only (S46B24R)
Location of Auxiliary Battery Auxiliary Battery (Sealed-type)
Hydrogen Drain Port Battery Temp.

Sensor

Auxiliary Battery Jump Start Terminal
04 09 Prius Main Junction Block Jumper Cable Tab
Negative Jumper Cable
Positive Jumper
Cable
10 & later Prius

Emergency Stop & Start Function
2010 Prius
If vehicle does not appear to READY OFF, change
Power source mode
If parking lock actuator Power Source Mode

malfunctions, it cannot shift OFF is not possible
position into P
Parking Brake is Vehicle

applied Stopped
READY Power Source Mode OFF is possible

Battery Service
Model Auxiliary Battery Battery Charger
01 03 Prius S34B20L
Special Smart charger:
S55D23L 00002-YA122-01*
Optional battery - See TSB EL014-03
Only perform a slow charge (3.5 A
04 09 Prius S34B20R or less).
S46D24R (on vehicles w/smart key

and/or Navigation)
10 & later Prius S46B24R Only perform a slow charge (4.2 A

or less).
Highlander Hybrid Lead-Acid: 55B24L Only perform a slow charge (5.0 A

or less) (Associated #ASE 6003 or
Christie #CAPPDQ)
Camry Hybrid S65D26R Only perform a slow charge (5.0 A
or less).


Emergency Response Guide
www.techinfo.toyota.com

[END Module 9 General Service]

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Course 071 Toyota Hybrid System

071 Toyota Hybrid System 1

071 Toyota Hybrid System 2

ILD 1: Transaxle Assembly Parts Identification

Worksheet 3: High Voltage System

ILD 4: Highlander Hybrid EPS on Pico Scope

Worksheet 5: Techstream (Hybrid EPS Initialization,

071 Toyota Hybrid System 3

071 Toyota Hybrid System 4

Toyota has been

071 Toyota Hybrid System 5

071 Toyota Hybrid System 6

071 Toyota Hybrid System 7

Rear Drive Unit

071 Toyota Hybrid System 9

Rear Drive Unit

071 Toyota Hybrid System 11

071 Toyota Hybrid System 12

All hybrid system high-voltage wire harnesses are orange.

071 Toyota Hybrid System 13

071 Toyota Hybrid System 14

071 Toyota Hybrid System 15

071 Toyota Hybrid System 16

071 Toyota Hybrid System 17

071 Toyota Hybrid System 18

071 Toyota Hybrid System 19

071 Toyota Hybrid System 20

071 Toyota Hybrid System 21

071 Toyota Hybrid System 22

071 Toyota Hybrid System 23

Insert the key (non- Push the POWER

071 Toyota Hybrid System 24

071 Toyota Hybrid System 25

071 Toyota Hybrid System 26

READY Light Malfunction Indicator Light

Master Warning Light

071 Toyota Hybrid System 27

071 Toyota Hybrid System 28

071 Toyota Hybrid System 29

Planetary Gear Unit

071 Toyota Hybrid System 30

071 Toyota Hybrid System 31

071 Toyota Hybrid System 32

More compact, more light

Motor rotational speed was

Resolver Stator Rotor

071 Toyota Hybrid System 34

Detects magnetic pole position

071 Toyota Hybrid System 35

071 Toyota Hybrid System 36

Compound Gear Unit

Counter Driven Gear

Differential Gear Unit

071 Toyota Hybrid System 37

Compound Gear Unit

Counter Drive Gear

071 Toyota Hybrid System 38

Ring Gear Carrier

071 Toyota Hybrid System 39

A coil & torque limiter provide damping

071 Toyota Hybrid System 40

Drain Plug Drain Plug

071 Toyota Hybrid System 41