1. Contents Click a Section Tab New Model PRIUS 2009
Instructor & Technical Staff

2. P410 Hybrid Transaxle
Electric Shift Lever System
Suspension
Brake
Brake Control System
Steering

3. P410 Hybrid Transaxle Overall
New Model PRIUS 2009
P410 Hybrid Transaxle
Overall
P410 hybrid transaxle mainly consists of the following components
Compound Gear Unit
Power Split Planetary Gear (Right Side)
Motor Speed Reduction Planetary Gear (Left Side)
MG2
Oil Pump (Mechanical Type)
Transaxle Damper
MG1
Basic operation and construction are the same as the P310 hybrid transaxle on HIGHLANDER HV / RX400h.
Final Drive Gear
Final Driven Gear
Counter Driven Gear
Differential Gear Unit
Instructor & Technical Staff

4. P410 Hybrid Transaxle Specification Transaxle Type P410 (New PRIUS)
(RX400h)
Shift Pattern
P–R–N–D–B 
Total Speed Reduction Ratio
3.267
3.542
Power Split Planetary Unit
No. of Ring Gear Teeth 78
No. of Pinion Gear Teeth 23
No. of Sun Gear Teeth 30
Motor Speed Reduction Planetary Gear 58 18 22
Counter Gear
No. of Drive Gear Teeth 54
No. of Driven Gear Teeth 55
Final Gear 24 25 77
Fluid
Type
ATF WS
Capacity [L (US qts, Imp. qts)]
3.3 (3.5, 2.9)
4.2 (4.4, 3.7)
Weight (Reference)*1 [kg (lb)]
92 (203)
117 (258)
Compound Gear Unit
*1: The figure shown is the weight with the oil fully filled.

5. P410 Hybrid Transaxle Gear Train Power Split Planetary Gear
New Model PRIUS 2009
P410 Hybrid Transaxle
Gear Train
Power Split Planetary Gear
Compound Gear Unit
Motor Speed Reduction Planetary Gear
Engine
Oil Pump
Transaxle Damper
MG2
MG1
The engine, MG1 and MG2 are mechanically joined via the compound gear unit.
Counter Driven Gear
Differential Gear Unit
Final Drive Gear
Instructor & Technical Staff

6. P410 Hybrid Transaxle Gear Train MG2 MG1 Engine
New Model PRIUS 2009
P410 Hybrid Transaxle
Gear Train
Motor Speed Reduction Device
Sun Gear: MG2
Planetary Carrier: Fixed
Rear Gear: Compound Gear (to Wheels)
Power Split Device
Sun Gear: MG1
Planetary Carrier: Engine
Ring Gear: Compound Gear (to Wheels)
MG2
MG1
Engine
The power split planetary gear unit splits the motive force of the engine two ways: one to drive the wheels, and the other to drive MG1, so that MG1 can function as a generator.
The motor speed reduction planetary gear unit, whose purpose is to reduce MG2 speed, is used to enable the high-output MG2 to adapt optimally to the power split planetary gear unit. - Motor Speed Reduction Ratio: 2.64
To Front Wheel
Instructor & Technical Staff

7. P410 Hybrid Transaxle Compound Gear Unit
Each planetary ring gear is integrated with the compound gear unit.
Furthermore, this compound gear unit is integrated with a counter drive gear and parking gear.
Counter Drive Gear
Parking Lock Gear
Ring Gear
(Motor Speed Reduction Planetary Gear)
Ring Gear
(Power Split Planetary Gear)
Motor Speed Reduction Planetary Gear Unit
Power Split Planetary Gear Unit
Counter Drive Gear (Compound Gear)
[Compound Gear Unit]

8. P410 Hybrid Transaxle Transaxle Damper
New Model PRIUS 2009
P410 Hybrid Transaxle
Transaxle Damper
Two types of damping characteristics are adopted
Low torsion-type coil spring damper
Dry single-plate friction material prevents the damage to the transaxle by the excessive engine torque by slipping
Transaxle Damper
Reduces shock which occurs when kinetic energy is transmitted
Instructor & Technical Staff

9. P410 Hybrid Transaxle MG Lubrication System
New Model PRIUS 2009
P410 Hybrid Transaxle
Lubrication System
Final gear with an oil sling type lubrication mechanism
Oil catch tank is used in order to supply oil to each gear train from there in a stable manner.
Oil Catch Tank
Oil Catch Tank
Oil Hole MG
Two types of the lubrication System
Trochoid Type Oil Pump: As with the previous model and P310 hybrid transaxle is lubricated by a trochoid type oil pump placed on the main shaft (Driven by the engine via main shaft).
Oil Sling Type Lubrication Mechanism: Oil catch tanks temporarily store the fluid that is slung up, and they supply oil to the different parts of the gear train.
Motor Cooling
Final Gear
Instructor & Technical Staff

10. Service Point (P410 Hybrid Transaxle)
New Model PRIUS 2009
Service Point (P410 Hybrid Transaxle)
Lubrication System
Drain plug and filler plug for hybrid transaxle fluid
Filler Plug for Hybrid Transaxle Fluid (10 mm Hexagon)
Front
Type of Hybrid Transaxle Fluid: TOYOTA Genuine ATF WS or equivalent
Maintenance Interval: Same as the previous model
Drain Plug for Hybrid Transaxle Fluid (10 mm Hexagon)
Drain Plug for Hybrid System Coolant (10 mm Hexagon)
Instructor & Technical Staff

11. Service Point (P410 Hybrid Transaxle)
New Model PRIUS 2009
Service Point (P410 Hybrid Transaxle)
Lubrication System
Add hybrid transaxle fluid
Filling method is the same as the conventional manual transaxle
0 to 10 mm (0.394 in.)
Check that the fluid level is between 0 to 10 mm (0 to in.) from the lowest position of the inner surface of the transaxle filler plug opening.
Filler Plug for Hybrid Transaxle Fluid
New PRIUS
Previous Model
Coolant Type
TOYOTA Genuine ATF WS 
Capacity
3.3 liters
(3.5 US qts, 2.9 Imp. qts) —
Maintenance Interval
Inspect / Replace
Same as previous model
Instructor & Technical Staff

12. P410 Hybrid Transaxle Cooling System
Cooling system that is independent from the engine cooling system is provided to cool the inverter with converter assembly, MG1 and MG2
Inverter with Converter Assembly
HV Radiator Reserve Tank
HV Radiator (for Inverter)
Inverter with Converter Assembly
HV Radiator Reserve Tank
HV Water Pump with Motor
HV Radiator
HV Transaxle
HV Water Pump with Motor

13. Electric Shift Lever System
Feature
This system changes the shift range using a shift-by-wire technology
Compact shift lever is used. It’s a momentary shift type that returns to the home position when the driver’s hand is released
[Shift Position Indicator]
P Position Switch
Operation signal
Only connected electrically
Shift Lever
Parking Lock Actuator

14. Electric Shift Lever System
System Diagram
Shift Lever Assembly
Transmission Control ECU
Parking Lock Actuator Relay
P Position Switch
Parking Lock Actuator
Rotation Angle Sensor
Parking Lock Motor
P Position Indicator Light
V Bus No.1
DLC3
Certification ECU
LIN
Immobiliser Code ECU
Power Management Control ECU (HV CPU)
Combination Meter
Shift Lever Position Sensor
Shift Position Indicator
Shift Sensor
Master Warning Light
Select Sensor
Buzzer
Multi-information Display

15. Electric Shift Lever System
Parts Location
Multi-information Display
Master Warning Light
Shift Position Indicator
Select Sensor
Power Management Control ECU (HV CPU)
Shift Sensor
Transmission Control ECU
Certification ECU
Selector Lever Assembly
Immobiliser Code ECU
P Position Switch
P Position Indicator Light
Parking Lock Actuator

16. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Shift Lever and Shift Position Indicator
Shift lever is designed to always return to its home position. Therefore, shift position that is current selected can be checked on the shift position indicator
Current Shift Position Indication
Operated by driver
P Position
R Position
N Position
Returns automatically
D Position
B Position
NOTE: When the shift lever is in a position other than D or B, the B position indicator will turn off.
Shift Position Indicator
Instructor & Technical Staff

17. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Shift Control
Table below shows how the shift lever / P position switch operation are controlled at each shift position
Power Source Status
Operation
Shift Position P R N D B
IG-OFF -
Unable to change the shift position
ACC
Shift Lever
P Position Switch
IG-ON
READY
READY >>> IG-OFF
AUTO P Function
When the power switch is turned off with the vehicle stopped, the shift position is automatically changed to P.
: Current Position : Positions to which shift position can be changed
: with brake pedal depressing : with stopped vehicle : Available always
Instructor & Technical Staff

18. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Reject Function
To ensure safety, this system might not change the shift position even if the driver operates the shift lever of P position switch in the following cases
Shift operation which causes reject function to operate
Shift position after rejection
The driver changes the shift position out of P without depressing the brake pedal
Held in P position
While driving
The driver changes the shift position to P with the P position switch operation
Changed to N position
The driver changes the shift position from D to R, from B to R or from R to D
The driver changed the shift lever position to B
from P
from R
from N
Held in N position
When shift rejection function operates, a buzzer sounds
Instructor & Technical Staff

19. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Shift Lever
Shift lever has built-in shift lever position sensor to detect the shift position (R, N, D and B)
Shift lever position sensor consists of a select sensor and shift sensor, and uses Hall ICs for position detection
Select Sensor
Shift sensor is the same as the previous model
Shift Sensor
Instructor & Technical Staff

20. Electric Shift Lever System
Select sensor
Detects the lateral movement of the shift lever
Sensor hall IC contains 2 circuits, one for main signal, one the sub signal (differing characteristics)
Hall ICs
Output Voltage
[V]
Output Characteristics 5
Center, B
R, N, D
Magnet Slider
(Connected to shift lever)

21. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Shift Lever
Shift sensor
Detects the longitudinal movement of the shift lever
Sensor hall IC contains 2 circuits, one for main signal, one the sub signal
Hall ICs
Magnets
Cross-section
Output Characteristics 5
Output Voltage
[V]
There are two sensor circuits (main and sub)
Main and sub circuits in the sensor are the same characteristic
LHD Model
D, B Side
R Side
RHD Model
R Side
D, B Side
Instructor & Technical Staff

22. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
P Position Switch
P position indicator light shows the conditions of the electric shift lever system as follows
P Position Indicator Light
Contents
Lights up
Shift position is in P
(Parking lock is in P position)
OFF
Shift position is not in P
(Parking lock is in non-P position)
Blink (First) [Approx. 4 Hz]
Parking lock actuator takes long to switch between P position and non-P position
Blink (Slow) [Approx. 0.5 Hz]
System malfunction
Blink (4 Hz): ON 0.13 sec. / OFF 0.13 sec.
Blink (0.5 Hz): ON 0.5 sec. / OFF 1.5 sec.
Parking switch
Instructor & Technical Staff

23. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Parking Lock Control
Upon receiving an actuation signal from the P position switch via transmission control ECU, the motor rotates to engage or disengage the parking lock mechanism
Compound Gear
Parking Lock Gear
Adoption of a parking lock actuator realized the electronic shift lever
Parking Lock Mechanism
Parking Lock Actuator
Instructor & Technical Staff

24. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Parking Lock Control
Parking lock actuator (SR motor)
Parking lock actuator mainly consists of a switched reluctance motor and a cycloid reduction mechanism
Rotation angle sensor consists of 2 Hall ICs
Reduction Mechanism
Shift Control Motor
W Phase
Magnet
Coil
V Phase
U Phase
Rotation Angle Sensor (Hall IC)
The switched reluctance motor is mainly composed of coil, stator, rotor and rotation angle sensor, and brushes and magnets are not used
Output Shaft
Stator
Rotor
[Switched Reluctance Motor]
Instructor & Technical Staff

25. Reference (Electric Shift Lever System)
New Model PRIUS 2009
Reference (Electric Shift Lever System)
Parking Lock Control
Parking lock actuator (SR motor)
Electric current is passed through the stator coil. The coil becomes electromagnet, and attracts the rotor (rotor rotates)
Electromagnet
: Electric current flows
Magnetism U V W U V W U V W
Rotate clockwise: W > V > U > W > V > U > …
Rotate counterclockwise: W > U > V > W > U > V > …
Instructor & Technical Staff

26. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Parking Lock Control
Parking lock actuator (Cycloid reduction mechanism)
Cycloid reduction mechanism ensures complete releasing operation for parking lock when vehicle is parked on slope road in which requires a high torque
Reduction Mechanism
Shift Control Motor
Inside Gear
(61 teeth)
Eccentric Plate Center
Outside Gear
(60 teeth)
Magnet
Motor Input Shaft Center
Eccentric Plate
Rotation Angle Sensor (Hall IC)
This mechanism consists of an eccentric plate that is mounted on the motor output shaft, an inside gear (61 teeth) that is secured to the housing, an outside gear (60 teeth), and an output shaft that rotates in unison with the outside gear
Along with the rotational movement of the eccentric plate, which rotates in unison with the motor output shaft, the inside gear pushes against the outside gear, while meshing. The outside gear, which has 1 tooth less than the inside gear, rotates 1 tooth less per rotation of the eccentric plate. As a result, the output shaft, which rotates in unison with the outside gear, outputs the rotational movement of the motor at a reduction ratio of 61.
Output Shaft
Output Shaft
[Image of Cycloid Reduction Mechanism]
* Operation same as VGRS reduction gear
Instructor & Technical Staff

27. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
Parking Lock Control
Parking lock mechanism
The engagement of the parking lock pawl with the parking gear that is integrated with the compound gear locks the movement of the vehicle
[Unlock Condition]
Parking lock actuator rotes
Parking lock lever is rotated and the parking lock rod is pushed
Parking lock pawl is pushed up
Parking lock pawl engages with the parking gear
Parking Gear
Engage Portion
Parking Lock Lever
[Lock Condition]
The parking lock mechanism consists of a parking lock lever, parking lock rod, parking lock pawl and parking gear.
Parking Lock Pawl
Parking Lock Actuator
Parking Lock Rod
Instructor & Technical Staff

28. Electric Shift Lever System
New Model PRIUS 2009
Electric Shift Lever System
DTC
When the malfunction occurs in this system, the transmission control ECU stores the DTCs in its memory
DTC No.
Detection Item
P Position Indicator
C2300*
Actuator System Malfunction
Blink (Slow)
C2301*
Shift Changing Time Malfunction
C2303*
Short in Power Source Relay Circuit
Normal Operation
C2304*
Open or Short Circuit in “U” Phase
C2305*
Open or Short Circuit in "V" Phase
C2306*
Open or Short Circuit in "W" Phase
C2307*
Over Current Malfunction
C2308
EEPROM Malfunction
???
C2309
Open in B+ Circuit
C2310
Open or Short Circuit in Battery Circuit
C2311
Communication Error from HV ECU
C2315
HV System
U0146
Lost Communication with Body ECU
DTCs C2308, C2309 and U0146 are the newly adopted and DTC C2318 is discontinued from previous model.
*: Remove the “P COM MAIN” fuse (Fuse Box 7.5 A) to erase the these DTCs because the they cannot be erased with the tester
Instructor & Technical Staff

29. Electric Shift Lever System
DTC
Location of “P COM MAIN” fuse
Remove the “P COM MAIN” fuse for approx. 60 sec. to erase the some DTCs
“P COM MAIN” Fuse (7.5 A)

30. Electric Shift Lever System
Case of Emergency
To stop the hybrid system
If it cannot shift position into P, the power source mode can be turned off by applying the parking brake
If malfunction in parking lock actuator, it cannot shift position into P
Power Source Mode OFF is impossible
Parking Brake is applied
Vehicle Stopped
Power Source Mode OFF is possible
READY

31. Suspension Front Suspension
MacPherson strut type independent suspension
Shock Absorber
Multi-leaf Type Liner Control Valve
Stabilizer Bar
[Front Wheel Alignment (Unloaded vehicle)]
Tire Size
195/65R15
Tread
1525 mm (60.0 in.)
Caster
5°53’ (5.88°)
Camber
-0°13’ (-0.22°)
Toe-in
2.0 mm (0.08 in.)
King Pin Inclination
12°16’ (12.27°)

32. Suspension Rear Suspension Torsion-beam type suspension Shock Absorber
Multi-leaf Type Liner Control Valve
Axle Beam
Trailing Arm
[Rear Wheel Alignment (Unloaded vehicle)]
Tire Size
195/65R15
Tread
1520 mm (59.8 in.)
Caster
-1°29’ (-1.48°)
Toe-in
2.9 mm (0.11 in.)

33. Brake Specification Master Cylinder Type Single (Center Valve)
New Model PRIUS 2009
Brake
Specification
Master Cylinder
Type
Single (Center Valve)
Diameter
22.2 mm (0.87 in.)
Brake Booster
Hydraulic
Front Brake
Brake Type
Ventilated Disc
Caliper Type
PEAL57
Wheel Cylinder Diameter
57.22 mm (2.25 in.)
Rotor Size (D x T)
255 mm x 25 mm (10.0 in. x 0.98 in.)
Pad
T4146
Rear Brake
Solid Disc
CLA11H
38.18 mm (1.50 in.)
259 mm x 9 mm (10.2 in. x 0.35 in.)
NS254
Brake Control System
ABS with EBD, BA, TRAC (TRC), VSC,
Hill-start Assist Control and
Cooperative Control with EPS
Instructor & Technical Staff

34. New Model PRIUS 2009
Brake
Rear Brake
Build-in type disc brake that has a build-in parking brake mechanism is provided
Rear Brake Caliper
Check Ball
Input Shaft
PKB OFF
PKB ON
The structure is same as COROLLA/AURIS
Crank Lever
Disc Pad
Push Rod
Nut Sleeve
Parking Brake Cable
Disc Rotor
Instructor & Technical Staff

35. Service Point (Brake) Rear Brake Parking brake lever travel adjustment
New Model PRIUS 2009
Service Point (Brake)
Rear Brake
Parking brake lever travel adjustment
Check and adjust the parking brake lever travel
Confirm the clearance between operation lever and stopper
(at the parking brake released)
Stopper
0.5 mm or less
[Parking Brake Lever Travel Adjustment]
Release the parking brake pedal
Loosen the lock nut and adjusting nut to completely release the parking brake cable
Turn the adjusting nut until the parking brake pedal travel is corrected to be within the specified range
Using a wrench, hold the adjusting nut and tighten the lock nut
Operate the parking brake pedal a few times
Check the parking brake pedal travel
Check whether the parking brake drags or not
Confirm the clearance between the operation lever and stopper at the parking brake released Clearance: 0.5 mm (0.02 in.) or less
Operation Lever
Instructor & Technical Staff

36. Suddenly Braking Brake Emergency Brake Signal Feature
New Model PRIUS 2009
Brake
Emergency Brake Signal
Feature
This function blinks the stop light at sudden braking to reduce the risk of rear-end collision
Blinks automatically
This function blinks the stop light at sudden braking to reduce the risk of rear-end collision
This function is used only for the European and Australia models
Suddenly Braking
Instructor & Technical Staff

37. Brake Emergency Brake Signal System Diagram V Bus No.1
Yaw Rate and Acceleration Sensor
Skid Control ECU
Stop Light Control Relay
Stop Light
Speed Sensors
Stop Light Switch
Hazard Warning Light Switch
Hazard Warning Light

38. Operation Start Conditions Operation Cancel Conditions
New Model PRIUS 2009
Brake
Emergency Brake Signal
Operation Condition
Operation Start Conditions
SPD is more than 55 km/h (34 mph)
Driver depresses the brake pedal
Vehicle deceleration exceeded specified value
Operation Cancel Conditions
Driver release the brake pedal
Vehicle deceleration became less than specified value
Driver pushes the hazard warning light switch
During operation, stop light blinks at approx. 4 Hz
[Operation Start Conditions (AND)]
- SPD is more than 55 km/h (34 mph)
- Driver depresses the brake pedal
- Vehicle deceleration exceeded specified value
[Operation Cancel Conditions (OR)]
- Driver releases the brake pedal
- Vehicle deceleration became less than specified value
- Driver pushes the hazard warning light switch
Instructor & Technical Staff

39. Hydraulic Brake Booster
New Model PRIUS 2009
Brake Control System
ECB (Electronically Controlled Brake) System
A new ECB system changed the following items from the current ECB system to realize a compact and lightweight
The master cylinder, skid control ECU, sensors, solenoid valves and stroke simulator are integrated
The hydraulic brake booster is used as a mechanism back-up if the brake system fails
ECU
Solenoid Valves
Sensors
Stroke Simulator
Hydraulic Brake Booster
Master Cylinder
Stoke Simulator
Solenoid Valves
Sensors
Power Supply Unit
Capacitor is discontinued
Power Supply Unit
ECU
Capacitor
Capacitor
Current Model
New Model
Instructor & Technical Staff

40. Brake Control System System Diagram Brake Booster Pump
Brake Booster with Master Cylinder
Brake Pedal Stroke Sensor
Accumulator
ABS Motor Relay
V Bus No.1
Pump Motor
Power Management Control ECU
Speed Sensors
Skid Control ECU
Stroke Simulator
Main Body ECU
Brake Fluid Level Warning Switch
Solenoid Valves
ABS Main Relay
Power Steering ECU
Front Door Courtesy Light Switch (Driver)
Regulator Pressure Sensor
Yaw Rate & Acceleration Sensor
Skid Control Buzzer
Wheel Cylinder Pressure Sensor
Stop Light Switch
Steering Angle Sensor
Accumulator Pressure Sensor
Stop Light
Control Relay
Combination Meter

41. Brake Control System Layout of Main Component Slip Indicator
ABS Warning Light
Skid Control Buzzer
Brake Warning Light
Brake Pedal Stroke Sensor
Parking Brake Switch
Stop Light Control Relay
Power Management Control ECU
Brake Master Cylinder Reservoir
Steering Angle Sensor
Stop Light Switch
Yaw Rate and Acceleration Sensor
Main Body ECU
Brake Booster with Master Cylinder
- Brake Actuator
Brake Booster Pump Assembly
Engine Room No.1 Relay Block

42. Changes in Braking Force Apportionment
Brake Control System
Regenerative Brake Cooperative Control
The apportioning of the brake force between the hydraulic brake and the regenerative brake
Driver’s Demand
Braking Force
Hydraulic Braking Force
Regenerative Braking Force
Time
Changes in Braking Force Apportionment

43. Brake Control System Hydraulic Circuit Brake Master Cylinder Reservoir
Accumulator
Pump Motor
Brake Fluid Level Warning Switch
Hydraulic Brake Booster
: Accumulator Pressure Sensor
Stroke Simulator
: Regulator Pressure Sensor
Brake Actuator
: Wheel Pressure Sensor
: Linear Solenoid Valve
: Switching Solenoid Valve
: Pressure Holding Solenoid Valve
: Pressure Reduction Solenoid Valve
FR LH
FR RH
RR LH
RR RH

44. Brake Booster with Master Cylinder
Brake Control System
Brake Booster with Master Cylinder
Brake Actuator
Brake actuator that consists of actuator portion and skid control ECU changes the brake fluid path during the operation of brake control
Brake Booster with Master Cylinder
Brake Actuator
Skid Control ECU
2 Linear Solenoid Valves
4 Switching Solenoid Valves
8 Control Solenoid Valves
Regulator Pressure sensor
Wheel Cylinder Pressure Sensor
Accumulator Pressure Sensor
Brake Actuator

45. Brake Control System Brake Booster with Master Cylinder Brake Actuator
Solenoid Valve Operation
Solenoid Valves
Function
Linear Solenoid Valve
Controls the wheel cylinder pressure to generate a braking force responsive to a braking force requirement when the brake pedal is depressed normally
Switching Solenoid Valve
Switches the brake hydraulic path when the brake control system is activated
Control Solenoid Valve
Control the wheel cylinder pressure when the brake system is activated
Regulator Pressure sensor
This sensor converts into the electric signal the fluid pressure generated by the hydraulic brake booster, and transmits them to the skid control ECU
Wheel Cylinder Pressure Sensor
This sensor detects the fluid pressure of the respective wheel cylinders and transmits them to the skid control ECU
Accumulator Pressure Sensor
This sensor constantly detects the fluid pressure in the accumulator and transmits them to the skid control ECU

46. Switching Solenoid Valve
Brake Control System
Brake Booster with Master Cylinder
Brake Actuator
Solenoid Valve Operation
Solenoid Valves
OFF
Linear
Solenoid Valve
SLA
Close
SLR
Switching Solenoid Valve
SSC
SCC
SMC
Open
SRC
Control
FLH
FRH
RLH
RRH
FLR
FRR
RLR
RRR
SSC
SLA
SRC
SMC
SLR
FLH
FRH
RLH
RRH
SCC
FLR
FRR
RLR
RRR

47. Normal Braking Operation
Brake Control System
Brake Booster with Master Cylinder
Brake Actuator
Solenoid Valve Operation
Solenoid Valves
Normal Braking Operation
System Fails
Increase
Holding
Reduction
Linear
Solenoid Valve
SLA
ON (Half-open)
OFF (Close)
SLR
Switching Solenoid Valve
SSC
ON (Open)
SCC
SMC
ON (Close)
OFF (Open)
SRC
Control
FLH
FRH
RLH
RRH
FLR
FRR
RLR
RRR

48. [Hydraulic Brake Booster Cross Section]
Brake Control System
Brake Booster with Master Cylinder
Hydraulic Brake Booster
Hydraulic brake booster generates the hydraulic pressure in accordance with the amount of effort applied to the brake pedal by the driver
[Hydraulic Brake Booster Cross Section]
Hydraulic Brake Booster

49. Master Cylinder Piston
Brake Control System
Brake Booster with Master Cylinder
Hydraulic Brake Booster
Structure
Reservoir Tank
Reservoir Tank
Power Piston
Accumulator
Regulator Piston
Operating Rod
Brake Actuator
Booster Chamber
Front Wheel Cylinder
Rear Wheel Cylinder
Master Cylinder Piston
Spool Valve

50. Brake Control System Brake Booster with Master Cylinder
Hydraulic Brake Booster
Normal Operation
Reservoir Tank
From Accumulator
Reservoir Tank
Brake pedal is depressed
Booster Chamber
To Brake Actuator
To Front Wheel Cylinder
To Rear Wheel Cylinder

51. [Stroke Simulator Cross Section]
New Model PRIUS 2009
Brake Control System
Brake Booster with Master Cylinder
Stroke Simulator
Stroke simulator generates the brake pedal stroke in accordance with the driver pedal effort during braking
[Stroke Simulator Cross Section]
Piston
Rubber
When the brake system is failure, the switching solenoid valve (SSC) is closed and the fluid flow is shut off from the master cylinder.
Stroke Simulator
Brake Master Cylinder Reservoir
Hydraulic Brake Booster
Instructor & Technical Staff

52. [Accumulator Cross Section]
Brake Control System
Brake Booster Pump Assembly
The power supply portion which consists of the pump, pump motor, accumulator, relief valve and accumulator pressure sensor generates and stores hydraulic pressure
Accumulator
Pump Motor
[Accumulator Cross Section]
Pump Motor
Accumulator
Nitrogen Gas
Camshaft
Bellows
Pump
Brake Fluid

53. Service Point (Brake Control System)
Disposal of brake boost pump assembly
When discarding the accumulator, make a hole in the accumulator housing in order to discharge the inside gas using a drill
[Disposal Procedure]
Secure the accumulator in a vise
Using a drill, make a hole in the A of accumulator
Gas
Vise
Point
Area A
25 mm (0.98 in.) B
60 mm (2.36 in.) B A
CAUTION: Be careful when drilling because shards of metal may fly about, so always use proper safety equipment

54. Brake Control System Hill-start Assist Control
When starting uphill, this control maintains the hydraulic pressure to four wheels in order to prevent the vehicle from descending backward
Operating Conditions
When the following conditions are met, this control starts.
If the control is started, the buzzer sounds once.
Shift position is in other than P
The accelerator pedal is not depressed
The vehicle is at standstill
The parking brake is not applied
The brake pedal is further depressed
Cancel Conditions
When the one of following condition is met, this control is canceled.
If the control is canceled, the buzzer sounds twice.
Shift position is changed to P
The parking brake is applied
The brake pedal is depressed again
The brake pedal is released for several seconds
The brake pedal is depressed and kept continually for 3 minutes
If the control is canceled, the buzzer does not sound.
The accelerator pedal is depressed

55. Hill-start Assist Control Operation
Brake Control System
Hill-start Assist Control
System Operation
Brake pedal is further depressed
Fluid Pressure
Brake Pedal Depressing Force
Sound Once
Sound Twice
Control-start Fluid Pressure
Brake pedal is depressed
When the accelerator pedal is not depressed
Vehicle-stop Fluid Pressure
Vehicle Stops
Control Starts
Accelerator Pedal ON
Cancellation conditions are met
Hill-start Assist Control Operation

56. Brake Control System Spiral Cable with Steering Angle Sensor
New Model PRIUS 2009
Brake Control System
Spiral Cable with Steering Angle Sensor
Absolute angle type steering angle sensor is used
Model
PRIUS
Conventional Models
Sensor Type
Absolute Angle Type
Relative Angle Type
Rotation Angle Sensor
MREs 
Neutral Position
Position constantly memorized
Position when battery terminal is connected
After battery terminal is reconnected —
No need initialization
Required initialization*
Remove steering wheel, etc.
No need initialization /
Supply Part
With Spiral Cable
Steering angle
sensor only
Absolute angle type steering angle sensor is the same as AVENSIS and VERSO.
Specified Value: 7.7 degrees
*: When the gap more than specified value arises between memorized steering position and the steering position after the battery reconnected
Instructor & Technical Staff

57. Service Point (Brake Control System)
Spiral Cable with Steering Angle Sensor
Notice for steering angle sensor
Do not remove steering sensor from spiral cable
Combination Switch Assembly
Spiral Cable with Steering Angle Sensor
Notice:
Do not replace the spiral cable with the battery connected and the engine switch ON
Do not rotate the spiral cable with the battery connected and the engine switch ON
Ensure that the steering wheel is installed and aligned straight when inspecting the steering sensor
Do not remove the steering sensor from the spiral cable
If disassembly, replace a new one
Steering Angle Sensor
Spiral Cable
NOTE: Steering sensor is supplied with spiral cable

58. Brake Control System Combination Meter
When the following conditions are met, the warning light illuminates to warn the driver
Slip Indicator
Brake Warning Light / Red
Brake Warning Light / Yellow
ABS Warning Light
TRAC (TRC), VSC or Hill-start assist control operate
Illuminate -
Malfunction occurs in ABS, EBD or BA
Malfunction occurs in TRAC (TRC) or VSC
Blink
Malfunction occurs in the apportioning of brake
Parking brake is on or brake fluid level is low
Minor malfunction occurs in the brake system which does not affect brake force
Warning Light*
Conditions
*: The indicator is a design for –A model

59. Service Point (Brake Control System)
Preparation for replacement
When the parts related to the brake system are replaced, stop the pump motor and decompress the accumulator and brake actuator
[Disable Brake Control]
Wait at least 2 minutes after the power switch OFF
Disconnect the reservoir level switch connector
Connect the Intelligent Tester and turn the power switch to IG-ON
Turn the Intelligent Tester ON enter the following menu: Chassis / ABS/VSC/TRC / Active Test
Select “ECB Invalid”
Depress the brake pedal more than 40 times, and then check the brake pedal is no longer depressed
Finish “ECB Invalid”
NOTICE: Do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected

60. Service Point (Brake Control System)
New Model PRIUS 2009
Service Point (Brake Control System)
Air Bleeding
When the following items are replaced or installed, be sure to perform the air bleeding using the tester
Work Procedure
Bleed Brake Line
Bleed Brake Master Cylinder
Replaced/Installed Item
Flexible hose (front / rear)
Disc brake cylinder (front / rear)
Brake booster pump assembly
Brake booster with master cylinder
Brake master cylinder reservoir
Procedure
Wait at least 2 minutes after the power switch OFF
Remove the brake master cylinder reservoir filler cap
Add brake fluid into reservoir between MAX and MIN level
Connect the tester to DLC3
Turn the power switch to IG-ON
Perform “Chassis / ABS/VSC/TRAC / Air Bleeding”
Bleed
Brake Line
Select “Usual air bleeding” and replace brake fluid according to the tester
After replacing brake fluid, tighten each bleeder plug
- Front bleeder plug / Rear bleeder plug
Clear DTCs
Bleed Brake Master Cylinder
Select “ABS actuator has been replaced” and replace brake fluid according to the tester
- Front bleeder plug / Rear bleeder plug / Stroke simulator bleeder plug
[Vehicle Condition]
Shift lever is in P
Parking brake is applied
Instructor & Technical Staff

61. Service Point (Brake Control System)
Initialization and Calibration
After replacing the following parts, perform the initialization and calibration
Replacement
Initialization
Brake Pedal
Brake Pedal Stroke Sensor
Clearing the stored linear solenoid valve calibration data
Initialization and calibration of the linear solenoid valve
Brake Booster with Master Cylinder
Calibration
Yaw Rate and Acceleration Sensor
Clearing zero point calibration data
Yaw rate and acceleration sensor zero point calibration
Front Wheel Alignment Adjustment

62. Service Point (Brake Control System)
Initialization and Calibration
Linear solenoid valve initialization
Procedure
Vehicle Condition
Power mode is OFF
Shift lever is in P
Steering wheel is centered
Clearing the stored linear solenoid valve calibration data
Connect the tester to DLC3
Turn the power switch to IG-ON
Perform “Chassis / ABS/VSC/TRAC / Utility / Reset Memory”
Perform yaw rate and acceleration sensor zero point calibration
Initialization and calibration of the
linear solenoid valve
Turn the power switch OFF
Release the parking brake
Perform “Chassis / ABS/VSC/TRAC / Utility / ECB Utility / Linear Valve Offset”
Keep the vehicle stationary without depressing the brake pedal for 1 or 2 minutes
Check that interval between blinks of the brake warning light / yellow
Check that DTC C1345 is not output
0.125 sec.
0.125 sec. ON
OFF

63. Service Point (Brake Control System)
Initialization and Calibration
Yaw rate and acceleration sensor zero point calibration
Procedure
Vehicle Condition
Power mode is OFF
Shift lever is in P
Steering wheel is centered
Clearing zero point calibration data
Connect the tester to DLC3
Turn the power switch to IG-ON
Perform “Chassis / ABS/VSC/TRAC / Utility / Reset Memory”
Turn the power switch OFF
Yaw rate and acceleration sensor
zero point calibration
Perform “Chassis / ABS/VSC/TRAC / Utility / Test Mode”
Keep the vehicle stationary for 2 sec. or more
Check that the ABS warning light, brake warning light / yellow and slip indicator lights on for several seconds and then blinks
0.125 sec.
0.125 sec. ON
OFF

64. Service Point (Brake Control System)
New Model PRIUS 2009
Service Point (Brake Control System)
ECB (Electronically Controlled Brake) Invalid Mode
This mode allows the brake fluid to be replaced without using the Intelligent Tester
Blinking
OFF >>>IG-ON
within 60 seconds N P N P
Shift Position
<Select ECB (Electronically Controlled Brake system) Invalid Mode>
Perform the procedure listed below in 1 minute
Turn the power switch to IG-ON with the shift lever in P and parking brake set
Move the shift lever to N and then depress the brake pedal more than 8 times in 5 seconds
Move the shift lever to P and then depress the brake pedal more than 8 times in 5 seconds
Move the shift lever to P
Check that the brake warning light (yellow) is blinking
Depress 8 times or more within 5 sec.
Depress 8 times or more within 5 sec.
Depress 8 times or more within 5 sec.
Brake Pedal Operation
Instructor & Technical Staff

65. Service Point (Brake Control System)
New Model PRIUS 2009
Service Point (Brake Control System)
ECB (Electronically Controlled Brake) Invalid Mode
When either of the following condition is met, ECB Invalid Mode is canceled (Not resuming)
The shift lever is moved from P to either position
Turn the power switch to READY
Turn the power switch OFF
The parking brake is released
The vehicle speed is not 0 km/h (0 mph)
Illuminates
Instructor & Technical Staff

66. Front brake system malfunction
Brake Control System
Fail-safe
When the malfunction occurs in the brake system, the hydraulic brake booster supplies fluid pressure directly to the wheel cylinders
Malfunction Portion
Operation
Brake actuator stops
The fluid pressure generated in the hydraulic brake booster by the driver’s brake pedal operation is directly supplied to wheel cylinders
Accumulator pressure
is not supplied
The fluid pressure generated in the master cylinder of hydraulic brake booster is supplied only to front wheel cylinders
Front brake system malfunction
The fluid pressure generated in the hydraulic brake booster is directly supplied to rear wheel cylinders

67. Service Point (Brake Control System)
DTC for ECB (Electrically Controlled Brake)
DTC No.
Detection Item
C1202
Master Reservoir Level Malfunction
C1203
ECM Communication Circuit Malfunction
C1211
SLA Linear Solenoid
C1212
SLR Linear Solenoid
C1214
Hydraulic Control System Malfunction
C1225
SA1 Solenoid Circuit
C1226
SA2 Solenoid Circuit
C1227
SA3 Solenoid Circuit
C1228
STR Solenoid Circuit
C1242
Open in IG1 / IG2 Power Source Circuit
C1246
Master Cylinder Pressure Sensor Malfunction
C1247
Stroke Sensor Malfunction
C1249
Open in Stop Light Switch Circuit
C1252
Brake Booster Pump Motor on Time Abnormally Long
C1253
Pump Motor Relay Malfunction
C1256
Accumulator Low Pressure
C1257
Power Supply Drive Circuit
C1259
HV System Regenerative Malfunction

68. Service Point (Brake Control System)
DTC for ECB (Electrically Controlled Brake)
DTC No.
Detection Item
C1300
Skid Control ECU Malfunction
C1311
Open in Main Relay 1 Circuit
C1312
Short in Main Relay 1 Circuit
C1345
Linear Solenoid Valve Offset Learning Undone
C1352
Front Increasing Pressure Solenoid RH Malfunction
C1353
Front Increasing Pressure Solenoid LH Malfunction
C1356
Front Decreasing Pressure Solenoid RH Malfunction
C1357
Front Decreasing Pressure Solenoid LH Malfunction
C1364
Wheel Cylinder Pressure Sensor Malfunction
C1365
Accumulator Pressure Sensor Malfunction
C1368
Linear Solenoid Valve Offset Malfunction
C1391
Accumulator Leak Malfunction
C1392
Stroke Sensor Zero Point Calibration Undone
C1451
Motor Drive Permission Malfunction
U0073
Control Module Communication Bus OFF
U0293
Communication Error from HV ECU

69. [Models with brushless type power steering motor]
New Model PRIUS 2009
Steering
EPS (Electrical Power Steering) System
Column assist type EPS system is used
Steering Column Assembly
Torque Sensor
Rotation Angle Sensor
Power Steering Motor
Power Steering ECU
[Models with brushless type power steering motor]
[Specification]
Brushless type power steering motor is used for –W, -Q and Mexico models, and models with 215/45R17 tires
Type
Vehicle Speed Sensing Type
Gear Ratio (Overall)
18.5
No. of Turns Lock to Lock
2.81
Rack Stroke [mm (in.)]
70.1 (2.76)
Instructor & Technical Staff

70. Steering System Diagram Steering Column Assembly Power Steering ECU
New Model PRIUS 2009
Steering
System Diagram
Steering Column Assembly
Power
Steering ECU
Torque Sensor
Rotation Angle Sensor*
Boost Converter*
Power Steering Motor
V Bus No.1
Boost converter is provided in the power steering ECU
Boost converter converts the voltage of the battery and supplies the power source to the motor
Power steering ECU uses the CAN protocol for diagnosis communication
DLC3
Steering Angle
Sensor
Combination Meter
Skid Control ECU
Vehicle Speed Signal
Power Management Control ECU
*: Models with brushless type power steering motor
Instructor & Technical Staff

71. Steering Major Difference from previous PRIUS Item New Model
Previous Model
Assist Type
Column Assist Type 
Power Steering ECU
N.A.
With Temperature Sensor
With Boost Converter
Motor
DC Motor
3-phase Brushless Motor
Rotation Angle Sensor
Resolver Type
Torque Sensor
Hall IC Type
Inductance Type
Reduction Mechanism
Worm and Wheel Gear

72. Steering Major Difference from previous PRIUS Item New Model
Previous Model
Multi Display
N.A.
PS Warning
Warning Light
P/S Warning Light
Master Warning Light
Initialization and Calibration
Necessary 

73. Service Point (Steering)
New Model PRIUS 2009
Service Point (Steering)
Initialization and Calibration
Perform the initialization and calibration of EPS system in the following cases
Rotation angle sensor initialization
Torque sensor zero point calibration
Assist Map Writing
Power steering ECU is replaced
Steering column assembly is replaced
Steering effort differs between left and right
Brushless type motor O
[Rotation Angle Sensor Initialization and Torque Sensor Zero Point Calibration]
<Precondition>
Connect the tester (Techstream or Intelligent tester) to DLC3
Turn the power switch to IG-ON
Turn the tester on
Enter the following menu: Chassis / EMPS / Data List
Check the values of the following item: IG Power Supply Standard Voltage: 10 to 14 V
<Initialization and Calibration>
NOTICE: Initialization and calibration cannot be performed when DTCs (C1516 and C1526) are stored.
Enter the following menu: Chassis / EMPS / Utility / Torque Sensor Adjustment
[Assist Map Writing]
NOTICE: If the DTC (C1581) is output after torque sensor zero point calibration, perform assist map writing.
Turn the power switch to READY
Enter the following menu: Chassis / EMPS / Utility / Signal Check
Check for DTCs
Instructor & Technical Staff