Toyota Hybrid Presentation - Start Here · 2016-03-25Toyota Hybrid Presentation - Start Here

1071 Toyota Hybrid System

WelcomeWelcome

Course 071 Toyota Hybrid System


• Hybrid System Overview• Transaxle Operation

Day One

Day Two

Day Three

• High Voltage System• Engine

• Brake System• Electric Power Steering• Air Conditioning• Multiplex Communication• Hybrid General Maintenance

Course Agenda


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)

Hybrid Transaxle• Motor / Generator 1• Motor / Generator 2

Inverter

1NZ-FXE Engine

HV Battery

‘01 – ‘03 Prius


HV Transaxle- Motor Generator 1 (MG1)- Motor Generator 2 (MG2)

Inverter Assembly HV Battery

Rear Drive Unit- Motor Generator Rear (MGR) (4WD-i Only)

Engine

Hybrid System Overview (THS II)Highlander Hybrid


‘01 – ‘03 Prius…1NZ-FXE (1.5L)‘04 – ‘09 Prius….1NZ-FXE (1.5L)‘10 up Prius……2ZR-FXE (1.8L)Highlander HV…3MZ-FE (3.3L)Camry HV…..…..2AZ-FXE (2.4L)

Hybrid System EnginesHighlander Hybrid


Hybrid Transaxle

- MG1

- MG2

Rear Drive Unit

- MGR (shown)

Hybrid Transaxle

- MG1

- MG2

Rear Drive Unit

- MGR (shown)

HV Transaxle- Motor Generator 1 (MG1)- Motor Generator 2 (MG2)

Rear Drive Unit- Motor Generator Rear (MGR) (4WD-i Only)

Hybrid Drivetrain ComponentsHighlander Hybrid


Inverter

• Controls current to motor generators

• Also provides correct voltages to other systems.

Inverter Assembly



HV Battery

HV Battery

• Stores electrical energy to drive the system



Hybrid Vehicle Safety Precaution2010 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


Insert the key (non-Smart Key equipped, ’04 – ‘09 Prius only)

ACC

OFF

IG-ON

READY

Push the POWER switch with the brake

pedal depressed

Vehicles enters READY mode

Push Button Start


Worksheet 1

Walkaround


Worksheet 2

Test Drive


Warning Lights‘04 – ‘09 Prius

READY Light

Master Warning Light

Malfunction Indicator Light

Low temperature indicatorlight


[END Module 1 Overview]


TransaxleOperation


Hybrid Transaxle‘01 – ‘03 Prius

MG1

MG2

Planetary Gear Unit

Silent Chain

Transaxle Damper


Construction of MG1‘01 – ‘03 PriusRotorStator Coil

Resolver


Construction of MG2‘01 – ‘03 Prius

Stator Coil Rotor

Resolver


Motor/Generators2010 Prius

• Total weight is reduced approximately 33% • MG2 maximum output is increased to 80 HP

MG1

MG2

Previous Model 2010 Prius PRIUS

More compact, more light weight design achieved through centralized winding of the coils.

Motor rotational speed was significantly increased, improving power performance

P112 P410


Construction of MGRHighlander Hybrid

Stator RotorResolver


Speed Sensor (Resolver) Operation

• Detects magnetic pole position

• HV ECU uses the Resolver as a speed sensor and calculates position variations

Coil A

Coil B

Coil C

MagnetizedSide

OutputSideRotor

Stator


Permanent Magnet Motor Generator


P410 Hybrid Transaxle2010 Prius

MG2

Compound Gear UnitPower Split Planetary

Gear (Right Side)Motor Speed Reduction

Planetary Gear (Left Side)

Oil Pump (Mechanical)

MG1

Final Driven Gear

Counter Driven Gear

Differential Gear Unit

Transaxle Damper

Final Drive Gear


Compound Gear Unit - Components2010 Prius

Compound Gear Unit

Power Split Planetary Gear Unit

Counter Drive Gear (Compound Gear)

Motor Speed Reduction Planetary

Gear Unit


Compound Gear Unit - OperationHighlander Hybrid

MG2 MG1

Engine

Carrier

CounterDriven Gear(To Wheels)

Carrier

Ring Gear


Transaxle Damper2010 Prius

• A coil & torque limiter provide damping

Transaxle Damper

Coil spring

Torque limiter


P112 Hybrid Transaxle Service ‘04 – ‘09 Prius

Adopts a shift control actuator Oil pan is

discontinued & WS type ATF is used

Drain Plug(for ATF)

Filler Plug(for ATF)

Drain Plug(for Coolant)


P410 Hybrid Transaxle Service2010 Prius

Fluid Type WS

Capacity 3.5 qts

Maintenance Interval (initial)

100,000 miles

Maintenance Interval (subsequent)

50,000 miles

Drain Plug for Hybrid Transaxle Fluid

Filler Plug for Hybrid Transaxle Fluid

Drain Plug for Hybrid System Coolant


P311 Hybrid Transaxle ServiceCamry Hybrid

WS Fluid Drain Plug (10mm hex)

WS Fluid Fill Plug (10mm hex)

Hybrid System Coolant Drain Plug (10mm hex)

0 to 0.20 in.


Shift Control – P111‘01 – ‘03 Prius

Shift Position Sensor

HVECU Engine

ECU(ECM)

Combination Meter

BEAN


Shift Assembly – P112‘04 – ‘09 Prius

Select Sensor

Shift Sensor


Shift Control Actuator – P112‘04 – ‘09 Prius

Shift Control Actuator

Cycloid Reduction Mechanism

Rotation AngleSensor

Rotor

Stator &Coil


Parking Lock Mechanism – P112‘04 – ‘09 Prius

Request

Hybrid Transaxle

Parking Lock Mechanism

Shift Control Actuator

T/M Control

ECUHV ECU

Control

Position“P” or “Not P”

Parking Switch

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.

… and apply the parking

brake.

To solve this problem, stop the

vehicle…

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


Drive Modes2010 PriusECO MODE

• Moderates the response to accelerator pedal operation to optimize fuel economy

• Moderates the A/C performance to optimize fuel economy

EV Mode• Driving with only the electric motor

PWR MODE• Optimizes acceleration performance

by increasing the motive force in relation to accelerator pedal operation

Accelerator Pedal Opening Angle

PWR Mode

Normal

ECO Mode

Mot

ive

Forc

e O

utpu

t


Service Tip - P311Camry Hybrid

• Transaxle Control Cable Adjustment

Slider

Shift Cable

4

5

Lock Piece

3

1

2

Shift to N range


Instructor Led Demo

Transaxle Assembly & Parts Identification


[END Module 2 Transaxle Operation]


High VoltageSystem


Certified Hybrid Vehicle Technician

CAUTIONCAUTION

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


Engine Room Junction Block

Power Cable Routing – Prius‘01 – ‘10 Prius

Inverter HV Battery

AuxiliaryBattery

A/C Compressor Auxiliary Battery

InverterHV Battery

2001-2003 Prius 2004-2009 Prius

2010-up Prius

HV Battery

Inverter

A/C Compressor Junction Block

Engine Room Junction Block


Power Cable Routing – Other Models

Highlander Hybrid

Battery Smart Unit & HV Relay Assembly

A/C Compressor


DC-DC Converter Camry Hybrid

A/C Compressor

Power Steering Converter

HV Relay Assembly

Rear Drive Unit (MGR)



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 Hybrid274 VDC 202 VDC 288 VDC 245 VDC


HV Battery - Layout‘01 – ‘03 Prius

SMR (System Main Relay)

Battery ECU

Battery Pack Upper Case

HV Battery Module


HV Battery - Layout‘04 – ‘09 Prius

SMR 3

SMR 2

SMR 1

Battery ECU

HV Battery Module

Rear Bus Bar Module

Front Bus Bar Module


HV Battery - Components2010 Prius

CAUTION: The HV battery is a high-voltage component that only Certified Hybrid Technicians should service.

HV Battery (Battery Modules) Battery Smart

Unit

Temperature Sensors(for battery modules)

HV Junction Block Assembly

HV Battery Cooling Blower

HV Battery Temperature Sensor

(for intake air)


HV Battery State of Charge (SOC)

Example of change in SOC

Undercharged region

Overcharged region

Control region

Time

SOC

Target SOC control

Upper SOC control limit

Lower SOC control limit


System Main Relays (SMR)2010 Prius

Note: Do NOT remove SMRs on the HV junction block assembly.

Service Plug

SMRB

SMRP

SMRG

Res

isto

r

Bat

tery

Mod

ules

HV BatteryCurrent Senor

Power Management Control ECU (HV CPU)

HV Battery Current Sensor

Precharge Resistor

SMRB

SMRP

SMRGBattery Smart Unit


SMR Control

SMR2

SMR1

SMR3

Service Plug

(+) to Inverter

(-) to Inverter

GND to THS ECU

High-Voltage Fuse

Resistor


Prius – HV Battery Cooling

2010-up Prius

2004-2009 Prius

2001-2003 Prius


HV Battery Cooling

2007-2010 Camry Hybrid

2006-2007 Highlander Hybrid


Inverter


Inverter AssemblyHighlander Hybrid

Boost Converter288 VDC - 650 VDC

InverterAC - DC

DC-DC Converter288 VDC - 12 VDC

MG ECUControls inverter

components

HSD Inverter


Toyota Hybrid System Charger

Front

Back


Safety Steps


Hybrid Service Safety PrecautionsSee 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 InformationCode Display INF Code Information (Trouble Area)

P0AA6 Hybrid Battery Voltage System

Isolation Fault

526 Insulation abnormality of the entire high-voltage circuit

611 Electric Compressor & A/C Inverter612 HV Battery, Battery Smart Unit, HV

Relay Assembly613 Hybrid Transmission, Inverter with

Converter Assembly614 DC High-voltage Area


READY OFF & Securing Smart Key

Approx. 10 ft. radius (not to scale)

• 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.


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.

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

Maximum Use Voltage AC


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 side2. Roll the opening up 2 or 3 times3. Fold the opening in half to close it4. 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

Protective CoverRear Door Scuff Plate LH

3 Steps to remove Large type Service Plug

2 Steps to remove Small type Service Plug

1

2

2

3

1


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.

Time

High-voltage CondensersDischarge

Electricity 0V

Service plug removal MODEL Discharge 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

• 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.

Best Practices


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 HazardsHighlander Hybrid

Don’t touch!Don’t touch!

• If electrolyte is present at the bottom of the battery case, avoid contact with the fluid.


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 Repair

START

Potential Damage

Installation

Hydrogen Vent Hose


Service Plug Installation After Repair

Small Service Plug Installation: Large Service Plug Installation:

2

1

Click is heard

3

1

2


Precautions for DC-DC Converter2010 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 HybridV6 Engine: 208 HPFront Drive Motor: 165 HPRear Drive Motor: 67 HPHV Battery: + 60 HPActual HP 268 HP

Prius Gen 21.5L Engine: 76 HPFront Drive Motor: 68 HPHV Battery: + 34 HPActual HP 110 HP

Camry HybridEngine: 147 HPFront Drive Motor: 143 HPHV Battery: +45 HPActual HP 192 HP

Prius Gen 31.8L Engine: 98 HPFront Drive Motor: 80 HPHV Battery: + 35 HPActual HP 134 HP


2010 & Later Prius2ZR-FXE


2ZR-FXE Engine‘04 – ‘10 Prius

‘04-09 MY ‘10 & later

Engine 1NZ-FXE 2ZR-FXEDisplacement (liters) 1.5 1.8Engine Oil Capacity dry (qts) 4.3 5.0Engine Oil Capacity w/ filters (qts) 3.9 4.4Compression Ratio 13.0:1 13.0:1Horsepower 76 @ 5000 98 @ 5200Torque (ft. lbf) 85 @ 4200 105 @ 4000Maximum System Output (hp) 109 134Maximum Voltage 500 650Emission 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

Engine Coolant

Cross Section

EGR Gas

EGR Cooler

From EGR Cooler

To Intake Manifold

Valve

CoilEGR Valve

Silicon Chip

MAP Sensor (Vacuum Sensor)


Electric Water Pump2010 Prius

Electric Water Pump

ShaftMotor

Stator

Rotor

Electric Water Pump• No accessory belt• New Active Test and

Data List items• New DTCs for pump


Cooling System Components2010 Prius

Reservoir Tank

Electric Water Pump

Throttle Body

From Radiator

To Radiator

To Exhaust Pipe Gas Control Actuator

From Exhaust Pipe Gas Control Actuator

EGR Valve

EGR Cooler

Coolant Temperature Sensor

Air Release Valve

From Heater CoreTo Heater Core


Exhaust Heat Recirculation System2010 PriusCoolant Temperature Switch

Exhaust Pipe Gas Control Actuator

Valve

Engine Engine Coolant

Exhaust Gas

Valve is closed(Coolant Cold)

Valve is open(Coolant Warmed Up)

Rod

Combination Meter


Exhaust Heat Recirculation Parts2010 Prius

Exhaust Pipe Gas Control Actuator

Exhaust Pipe Gas Control Actuator Case

Exhaust Pipe Gas Control Stopper

Gasket


Engine Coolant Change2010 PriusAir Release Valve

Service Tip - follow Repair Manual procedures carefully & use the air release valve to remove all air from the system.

Radiator Drain Cock Plug

Air Release Valve

Reservoir Tank Cap

Cylinder Block Drain Cock Plug

Coolant Type SLLC

Capacity 7.7 qts

Maintenance Interval (initial)

100,000 miles

Maintenance Interval (subsequent)

50,000 miles


• 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).

Service Tips (Engine Coolant Change)

B Line

FULLLOW• After the engine has cooled, check that

coolant level is between FULL & LOW

2010 Prius


‘04 – ‘09 Prius1NZ-FXE


Coolant Heat Storage System‘04 – ‘09 Prius

Water Pump(for coolant heat storage system)

to heater core

Engine Coolant Temp. Sensor(for coolant heat storage system)

Engine Coolant Temp. Sensor(for engine control system)

Coolant Flow Control Valve

Water Pump (for heater)

Coolant Heat Storage Tank

Reverse View


Coolant Heat Storage Tank‘04 – ‘09 Prius

Bleeding air from the system is critical

Drain Plug

Outlet Temp. Sensor

to/fromWater Valve

Pump


3.5 V (VLV4)

4.5 V (VLV5)

2.5 V (VLV3)

2.5 V

Prius Coolant Heat Storage Operation‘04 – ‘09 Prius


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 Prius1NZ-FXE


Intake Manifold - 1NZ-FXE‘01 – ‘09 Prius

Intake Pipes

Throttle Control Motor

Throttle Position Sensor

Surge Tank


‘01 – ‘03 Prius

VIEW HC ADSORPTION CATALYST SYSTEM

ActuatorHC Adsorber

Bypass Valve ClosedTWC

TWC

Main Muffler

TWC with HC Adsorber

HC Adsorber and Catalyst (HCAC)


THS Engine Coolant Change

SpecificationsFluid Toyota Super Long Life

Coolant (SLLC)

Capacity 5.2 qt (4.9 L)Service Tip: Refer to the Repair Manual for details

Bleeder Point

Engine Coolant Fill


Highlander Hybrid 3MZ-FECamry Hybrid 2AZ-FXE


Highlander Hybrid – Engine Coolant Change

Specifications


Capacity 13.5 qt. with rear heater11.2 qt. without rear heater

Service Tip: Refer to the Repair Manual for details

2006 - 2007 Highlander Hybrid 2008 - 2010 Highlander Hybrid


Radiator Drain Cock Plug(Equipped with Vent Plug)


Radiator Cap


Radiator Drain Cock Plug(Equipped with Vent Plug)


Radiator Cap


Camry Hybrid – Engine Coolant Change

Radiator Cap

Cylinder Block DrainCock Plug

Radiator DrainCock Plug

Specifications


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

Steel Tank

Interior

Sub Tank


Fuel Sender Gauge‘01 – ‘03 Prius

BodyECU

MeterECU Display

Combination Meter

Fuel Sender Gauge

Float

Reed Switch


Inclination Sensors

‘01 – ‘03 Prius

Sender Gauge Signal

Combination Meter

InclinationSensors

Main Tank

Ambient Temp.Sensor

MeterECU

Fuel Sender Gauge

Body ECU

Combination Meter

InclinationSensors

Main Tank

Ambient Temp

Sensor

MeterECU

Fuel Sender Gauge

‘04 – ‘09 Prius


EVAP Control Components

‘01 – ‘03 Prius

Fresh Air Line

VSV (for Canister Closed Valve)

‘04 – ‘09 Prius


EVAP Control Components‘04 – ‘09 Prius

Air CleanerThrottle Valve

Refuel CheckValve

Filler Pipe

Charcoal Canister

VSV (for Canister Closed Valve)

Vapor Pressure Sensor

Fuel Tank

Trap Filter

VSV (for EVAP)

EVAP Line

ECM

VSV (for Purge Flow Switching Valve)

Fresh Air Line

ORVR REFUELING

PURGING


EVAPHighlander Hybrid:

3MZ-FE


Closed Fuel Tank SystemHighlander Hybrid

THS ECU

Canister

Fuel Outlet Valve(Closed)

Fuel Vapor Containment Valve

Pump Module


Refueling ProcedureHighlander Hybrid


EVAP‘10 & Later Prius:

2ZR-FXE


Fuel System2010 Prius

Key Off EVAP System

Bladderless, layered plastic fuel tank

Fuel Pump Assembly- Fuel Filter

- Pressure Regulator- Fuel Sender Gauge

12-hole Type Fuel Injector

Quick Connector

Fuel Delivery Pipe


Fuel System – Key OFF EVAP2010 Prius

Fuel Cut-off Valve

ECM

PurgeVSV

Canister Pressure Sensor

Air Inlet Line

Leak Detection Pump

Fuel Filler Check Valve

Fuel Tank

Vent Line

[Pump Module]

Charcoal Canister

Vent ValveAir Filter

Purge Line

* The purge VSV control has changed and the purge flow volume increased.


Diagnostic Inspection Modes

Change to IG OFF – inspection mode is canceled

OFF

IG-ON

(but not READY ON)

Depress 2 times

Accelerator Pedal

Depress 2 times

Depress 2 times

within 60 seconds

• FWD Inspection Mode

IG-ON

READY ON


[END Module 4 Engine]


Brake System


Electronically Controlled Brakes (ECB)

Brake Booster with Master Cylinder

Pump Assembly w/ Accumulator

Brake Master Cylinder Reservoir

Wheel Speed Sensor

Brake Pedal Stroke Sensor

Main Body ECUPower Management Control ECU

Steering Angle Sensor

Yaw Rate and Acceleration Sensor


Prius ECB Layout

2001–2003:Hydraulic Boosted

Master Cylinder

2004 to 2009:Electronic Brake Actuator

with Stroke Simulator2010-up:

Hydraulic Brake Boosterwith Stroke Simulator


Brake System Comparison

‘01 – ‘03 Prius ‘04 – ‘09 Prius ‘10 & later Prius Highlander Hybrid

Camry Hybrid

Regenerative Brake Cooperative Control ABS w/ EBD

Hydraulic Brake

Booster*

Electronically Controlled Braking (ECB)

- 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

Regenerative Braking Force

Hydraulic Braking Force

Braking Force

Time

Driver’s Demand

Changes in Braking Force Apportionment


Electronically Controlled Braking SystemHighlander Hybrid

Hydraulic Brake Force

Brake Force

Regenerative Brake Force

Skid Control ECU

Master Cylinder

Pressure Sensor


Hydraulic Power Source Portion

Hydraulic Control Portion

THS-II

EPS

: Electrical Signal: Fluid Pressure


Brake Pedal Stroke Sensor‘04 – ‘09 Prius

Sensor Lever


Stop Light Switch

Brake Pedal

Sensor Lever Rotational Angle

Volta

ge

SKS2

SKS1

5

1

0-15 0 60º


Accumulator/ Actuator


Master Cylinder

Brake Booster with Master Cylinder

Brake Actuator

StrokeSimulator

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


Brake Hydraulic Circuit2010 PriusAccumulator

Pump Motor

Hydraulic Brake Booster

: Regulator Pressure Sensor

: Accumulator Pressure Sensor

: Wheel Pressure Sensor

: Linear Solenoid Valve

: Switching Solenoid Valve

: Pressure Reduction Solenoid Valve

: Pressure Holding Solenoid Valve

Stroke Simulator

FR RHFR LH RR LH RR RH

Brake Actuator

Fluid Level Warning Switch


Warning Lights


Brake Control System - Combination Meter

2010 Prius

• Warning light illumination

Brake Warning

Light / Yellow

Brake Warning

Light / Red

ABS Warning Light

VSC Slip Indicator

TRAC (TRC), VSC or HAC operation - - - IlluminateMalfunction 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 - -

Warning Light

Conditions

Shown above is the 2010 Prius. Other Models are similar.


Service Details


ECB Utilities


Service Tip - Brake Fluid Level2010 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

2004 and later Prius2008 and later Highlander Hybrid

EPSEPSECUECU

Torque sensorTorque sensorDC motorDC motor

EPSEPSECUECU

Torque sensorTorque sensor

DC motorDC motor

2001–2003 Prius Camry Hybrid and 2006–2007 Highlander Hybrid

DC motor

Torque sensor


EPS - Torque Sensor

‘01 – ‘03 Prius

Torsion Bar

Detection Ring 1Detection

Ring 2

Detection Ring 3

Detection Coil Correction Coil

‘04 – ‘09 Prius

Torque Sensor Video Torque Sensor Animation

Torque Sensor DC Motor


EPS Steering System Diagram‘04 – ‘09 Prius

Torque Sensor

DC Motor

EPS ECU

Gateway ECU

Skid Control ECU Meter ECU

HV ECU

Multi Display•Vehicle Speed

signal

•Assist torque demand signal (for

Enhanced VSC*)

•Master Warning Light

•EPS Warning Display Request Signal to Multi

Display

•Warning display

•READY signal

DLC3


Steering System Diagram2010 Prius

Power Steering ECU


V Bus No.1

Boost Converter*

Combination Meter

Torque Sensor

Rotation Angle Sensor*

Power Steering Motor

Steering Column Assembly

*Models with brushless type motor

Power Management Control ECU

Skid Control ECU

•Vehicle Speed Signal

DLC3


Brushless & Brush Type EPS2010 Prius

Power Steering ECU

Steering Column Assembly- Brush-type Power Steering

Motor- Torque Sensor

Steering Column Assembly- Brushless-type Power

Steering Motor- Torque Sensor- Rotation Angle 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).

Power Steering ECU


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) or Brushless 3-phase Motor*, 2

Brush type

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 Initialization2010 Prius

• Perform initialization & calibration on 2010 Prius EPS as follows:

Repair Motor Type Rotation Angle Sensor

Initialization

Torque Sensor Zero

Point Calibration

Assist Map Writing

• ECU replacement• Column assy.

replacement• Left or right effort

differs

Brush O O

Brushless O O O


Service Tip – Spiral Cable2010 Prius

• Spiral Cable w/Steering Angle Sensor is a complete assembly

• Do not remove the steering angle sensor from the spiral cable

• Do not replace or rotate the spiral cable with the battery connected & engine switch ON

Combination Switch Assembly

Spiral Cable


Spiral Cable with Steering Angle Sensor

Tip: Ensure that the steering wheel is installed & aligned straight when inspecting the steering sensor.


EPS ComponentsHighlander Hybrid

THS ECU

EPS ECU

Steering Gear UnitSkid Control ECU

DC - DC Converter (for EPS)

Combination Meter

P/S Warning Light


EPS Steering SystemHighlander Hybrid

BEAN (Instrument Panel Bus)

Voltage: 288 volts

CAN

EPS ECU

Temperature Sensor

Voltage: 42 volts

Torque Sensor

Rotation Angle Sensor

Motor

DC-DC Converter(for EPS)

DLC 3

THS ECU

· READY signal

Skid Control ECU· Vehicle Speed signal· Assist torque demand signal

Meter ECU

· P/S Warning Light

Gateway ECU

HV Battery


2006-2007 Highlander Hybrid - Power Steering Precaution

‘06 – ‘07 Highlander Hybrid

The yellow power steering wire harnesses carry 42 volts.

The orange harness leading to the EPS DC-DC converter carries 288 VDC.


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

Insulation FilmPTC

Element

Electrode

‘01 – ‘03 Prius

PTC Element Brass

Plate

Aluminum Fin

‘07 & later Camry Hybrid


Electric Coolant Pump

• Provides stable heater performance even with engine stopped

Bypass Valve CloseFrom

EngineTo

Heater

’01 – ’03 Prius Highlander Hybrid

’04 – ‘09 Prius

From Engine

To Heater


Main Air Conditioning Components‘04 – ‘09 Prius

Electric Compressor

A/C Inverter

A/C Water Pump

Solar Sensor

Room Temp. & Humidity Sensor

A/C ECU

Heater Core PTC Heater

Evap. Temp. Sensor

Blower Fan

Clean Air Filter


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

Brushless Motor

Variable Scroll

Fixed Scroll

Oil Separator

Discharge Port

Motor Shaft

A/C Inverter

ES18 compressor ES27 compressor


ES14 Compressor Construction2010 Prius

Oil Separator

A/C Inverter(DC AC)

DC 201.6 V

Scroll Type Compressor

Caution: Use only ND11 type compressor oil.

Brushless Motor


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 Components2010 Prius

6 Cells 6 Cells

A/C Amplifier

Solar Ventilation ECU

Blower Motor

Air Inlet Control Servo Motor

Air Outlet Control Servo Motor

Blower Motor Relay

Ventilation Switch

Moonroof Solar Module


Precaution: Solar Ventilation System2010 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 Conditioning2010 Prius

A/C SystemPress & Hold

• Cools the cabin before entering vehicle. • Use A/C switch on the remote to activate.


PRECAUTION: Remote Air Conditioning

2010 Prius

PowerPower

HV Battery

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.


PlasmaclusterTM Generator

Positive and Negative Ions

+

--

-

+ +

+-

-

-

+

+

Plasmacluster Generator

2010 Prius

Camry Hybrid


Ejector Cycle System (ECS)2010 Prius

Condenser

Expansion Valve

Ejector

Capillary Tube

ECS Evaporator

Compressor

Upwind Side

Downwind Side

A – A Cross Section

Capillary Tube

Ejector

Top Tank

Bottom Tank

A

A

Evaporator(Upwind Side)

Evaporator(Downwind Side)


Ejector Cycle System (ECS)2010 Prius

To Evaporator (Upwind Side)

Ejector

From Evaporator (Downwind Side)

From Expansion Valve

Nozzle

Diffuser Portion

VacuumMixing Portion


Cabin Air Filter Maintenance2010 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 ContentsHighlander Hybrid

Mode Monitor Terminal

ContactRelays Fuses

SemiconductorRelays

Front

Power Distributor


• Vehicle Speed Signal

Automatic Headlight Beam Level‘04 – ‘09 Prius

Service Tip - Initialize system after repair

Combination Meter

Master Warning Light

Headlight LevelingActuator

Headlight BeamLevel Control

ECU

Rear HeightControl 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

Main Body ECU

J/B

Junction Block

2010 Prius


Painted Wire Harness

Front Door Wire Harness

Painted only near the connector

Color (Color Code)

•Black (B)•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

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.

’01 – ’03 Prius ’04 – ‘09 Prius ’10 & later Prius

Highlander Camry

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 (’06-’07)

5W-20(6)

0W-20 (’08-’09)

0W-20

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)


Lubrication System2010 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

Oil Filter Cap

Element

O-ring

Note: Do not remove the oil filter bracket clip when removing the oil filter cap assembly.


Prius - Tire & Wheel

* Extra load carrying capacity (XL) must be used** option

‘01 – ‘03 Prius

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)


Auxiliary Battery

Lead-calcium Alloy

’01 –’03 Prius ’04 – ‘09 Prius

TIP: • Take care not to damage temperature sensor during service.• Refer to Repair Manual for systems that must be initialized with a

battery disconnect.


Service - Auxiliary Battery2010 Prius

Do NOT perform a quick charge.• Replace with dedicated battery only (S46B24R)

Hydrogen Drain Port

Auxiliary Battery (Sealed-type)

Battery Temp. Sensor

Location of Auxiliary Battery


Auxiliary Battery Jump Start Terminal

‘10 & later Prius

Negative Jumper Cable

Positive Jumper Cable

Main Junction Block Jumper Cable Tab‘04 – ‘09 Prius


Emergency Stop & Start Function2010 Prius

• If vehicle does not appear to READY OFF, change Power source mode

If parking lock actuator malfunctions, it cannot shift

position into P

Vehicle Stopped

Parking Brake is applied

Power Source Mode OFF is possible

Power Source Mode OFF is not possible

READY


Battery Service

Model Auxiliary Battery Battery Charger

‘01 – ‘03 Prius S34B20L Special “Smart” charger:00002-YA122-01*

Only perform a slow charge (3.5 A or less).

S55D23L Optional battery - See TSB EL014-03

‘04 – ‘09 Prius S34B20R

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

http://www.techinfo.toyota.com/

http://www.techinfo.toyota.com/


[END Module 9 General Service]

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