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

2. Power Management Control System Lighting Multi-information Display
New Model PRIUS 2009
MPX System
Power Management Control System
Lighting
Multi-information Display
HUD (Headup Display)
Air Conditioner
Entry and Start System
Steering Pad Switch
Wire Harness
Instructor & Technical Staff

3. MPX (Multiplex Communication) System
New Model PRIUS 2009
MPX (Multiplex Communication) System
CAN and LIN Communication
V Bus & PM Bus : 500 kbps
Terminating Resistor
: With Gateway Function
: Master ECU for LIN
: Terminating Resistor
: Installed to the junction connector *
Seat Belt Control ECU
Parking Assist ECU *
V Bus No.2
A/C Amplifier
Heater Control Panel
Ultrasonic Sensors
Ultrasonic Sensors x2
Immobiliser Code ECU
Power Management Control ECU (HV CPU)
LIN
Power Management Bus
ECM
Skid Control ECU
Certification ECU
Transmission Control ECU
V Bus No.1
V Bus: 500 kbps
Power Management Bus: 500 kbps
Driving Support Bus: 500 kbps
LIN: 20 kbps
Steering Angle Sensor
Yaw Rate & Acceleration Sensor
Main Body ECU
Center Airbag Sensor Assembly
Power Steering ECU
Combination Meter
LIN
Power Window Motor Assy x4
Power Window Master Switch
Double Lock ECU
DLC3
Instructor & Technical Staff

4. MPX (Multiplex Communication) System
New Model PRIUS 2009
MPX (Multiplex Communication) System
Main Body ECU
Plug-in type main body ECU is used
It can replace only main body ECU
Main Body ECU
Plug-in type main body ECU is the same as RX350.
J/B
Junction Block
Instructor & Technical Staff

5. Service Point (MPX System)
New Model PRIUS 2009
Service Point (MPX System)
Main Body ECU
Removal
Main Body ECU
Push J/B lock portion and unlock the lock mechanism
Insert screwdriver to clearance between the J/B and the Main Body ECU, and disconnect the Main Body ECU connector from the J/B
Remove the Main Body ECU from the J/B 1
J/B 2 3
Connector Portion
Screwdriver
Instructor & Technical Staff

6. Service Point (MPX System)
New Model PRIUS 2009
Service Point (MPX System)
Main Body ECU
Installation
Contact
Set a new Main Body ECU to the J/B
NOTE: Do not touch the ECU connector
Rotate the Main Body ECU until the ECU lock portion is inserted into the lock mechanism
Push the Main Body ECU to lock the lock mechanism
NOTE: Click sound is heard from lock portion when locked
Check that the height of the rib portion of the J/B and the surface of the Main Body ECU is the same
1-1
1-2 2
Push Area 3
Lock Mechanism 4
ECU Surface
Rib Portion
Instructor & Technical Staff

7. Power Management Control System
New Model PRIUS 2009
Power Management Control System
Power Management Control ECU
The hybrid control, electric power control system, a gateway function and power source control are integrated to the power management control ECU
HV Battery Control
CAN Gateway
Function
Hybrid System
Control
Power Mode
Control
Power Management Control ECU
Realizing
simplified
systems
Instructor & Technical Staff

8. New Model PRIUS 2009
Lighting
Headlight
Headlight unit that used Halogen for low beam. Low beam unit adopted projector type
Low Beam
(Halogen)
Specification of Low Beam
- LED 32.4 W (10.8 W x3)
High Beam
(Halogen)
Instructor & Technical Staff

9. Multi-information Display
New Model PRIUS 2009
Multi-information Display
Hybrid System Indicator and Eco Driving Indicator
Hybrid system indicator informs the driver of the zone recommended for fuel-efficient driving
Eco driving indicator informs the driver that the vehicle is being driven in an environmentally friendly manner
Eco Driving Indicator
Eco driving indicator is available on the hybrid system indicator display and 5 min. / 1 min. consumption record display.
Hybrid System Indicator
Instructor & Technical Staff

10. Multi-information Display
New Model PRIUS 2009
Multi-information Display
Hybrid System Indicator and Eco Driving Indicator
The hybrid system indicator is divided into 3 areas (Charge, Eco, Power) *1 *2
Charge
Power
Eco
Area
Vehicle Condition
Hybrid System Indicator and
Eco Driving Indicator
Charge
Energy regeneration is occurring
Eco
*1: (Hybrid Eco Area)
A fuel-efficient hybrid driving state (Engine is frequently stopped)
*2: (Fuel-efficient Driving Area)
Fuel-efficient driving state
Power
The vehicle is driven by the motor and the engine
When the hybrid system indicator level indication is in the charging area or Eco area, the Eco driving indicator comes on.
Instructor & Technical Staff

11. Multi-information Display
New Model PRIUS 2009
Multi-information Display
Hybrid System Indicator and Eco Driving Indicator
Operating conditions [AND]
Hybrid System Indicator:
READY-ON state
The shift position is in D or B
Eco Driving Indicator:
READY-ON state
The shift position is in D
Vehicle speed is 4 km/h (2.5 mph) or more and 130 km/h (80 mph) or less
Vehicle is not in PWR mode or EV drive mode
MG1, 2 and inverter temp. is normal
Hybrid system is normal
Combination meter receives the following signals via CAN communication.
From the power management control ECU
- Hybrid system indicator level indication
- Eco driving indicator ON/OFF indication
- Shift position signal
- PWR and EV drive mode signal
- MG and inverter overheat signal
- Hybrid system malfunction signal
From the skid control ECU
- Vehicle speed signal
Instructor & Technical Staff

12. Multi-information Display
New Model PRIUS 2009
Multi-information Display
Hybrid System Indicator and Eco Driving Indicator
The operating diagram of the Eco driving indicator function
Large
Acceleration
(System Output)
The Eco driving indicator can be turned off by the setting mode of the multi-information display. (Default: ON)
Vehicle Speed
Fast
Instructor & Technical Staff

13. HUD (Headup Display) General
New Model PRIUS 2009
HUD (Headup Display)
General
Headup display provides the various information with good visibility
Vehicle Speed
Hybrid System Indicator
Cruise Control Warning
Headup display is standard equipment for –W and -Q.
Instructor & Technical Staff

14. HUD System Diagram Headup Display Headup Display Satellite Switch
New Model PRIUS 2009
HUD
System Diagram
Headup Display
Headup Display Satellite Switch
Display Image
Luminance Setting
Mirror Angle (Display Position)
Combination Meter
Power Management Control ECU
V Bus No.2
V Bus No.1
Light Control Sensor
Main
Body
ECU
Driving Support ECU
Instructor & Technical Staff

15. VFD: Vacuum Fluorescent Display
New Model PRIUS 2009
HUD
Headup Display
A mirror reflects the image that is displayed on a VFD
Virtual Image
Windshield Glass
Mirror
Mirror
Headup Display
VFD: Vacuum Fluorescent Display
VFD
VFD: Vacuum Fluorescent Display
Instructor & Technical Staff

16. HUD Headup Display Supply parts Combination Meter Mirror Glass
New Model PRIUS 2009
HUD
Headup Display
Supply parts
Combination Meter Mirror Glass
No.1 Combination Meter Mirror Case
Headup Display Assy
(Not supply parts)
Combination Meter Mirror (With Motor)
No.1 Combination Meter Mirror Plate
No.2 Combination Meter Mirror
Combination Display (VFD)
No.2 Combination Meter Mirror Case
The motor included in the combination meter mirror changes the angle of the mirror to adjust the vertical position of the virtual image.
Combination Meter Mirror Wire
No.2 Combination Meter Mirror Wire
Combination Meter Mirror ECU
No.2 Combination Meter Mirror Plate
Instructor & Technical Staff

17. Headup Display Satellite Switch
New Model PRIUS 2009
HUD
Headup Display Satellite Switch
Function
Switch
Function
HUD Main Switch
Changes or turns off the contents of the headup display
Display Position Adjustment Switch
Adjusts the vertical position of the virtual image
Display Luminance Adjustment Switch
Adjusts the luminance of the display
Headup Display Satellite Switch
[HUD Main Switch]
- Changes or turns off the contents of the headup display.
- The indicator light illuminates when the headup display is turned on.
- Momentary type switch
[NAVI Switch]
- Turns on / off the navigation display function.
- The indicator light illuminates when the navigation display function is turned on.
[Display Position Adjustment Switch]
- Vertical position of the virtual image is adjusted by changing the mirror angle using motor.
[Display Luminance Adjustment Switch]
- Luminance of the display is adjusted.
NOTE: Brightness of the display is automatically adjusted in accordance with the ambient light level using the signal from light control sensor.
Instructor & Technical Staff

18. Vehicle Speed + Hybrid System Indicator
New Model PRIUS 2009
HUD
Function
Following 5 items are displayed on headup display
Item
Display
Operation
Priority
Vehicle Speed
Vehicle speed is displayed 1
Vehicle Speed + Hybrid System Indicator
Vehicle speed, hybrid system indicator and Eco driving indicator are displayed 2
Navigation (turn-by-turn) display is displayed only when the NAVI switch indicator light illuminates.
Instructor & Technical Staff

19. New Model PRIUS 2009
HUD
Setting Mode
A vehicle speed that starts indicating vehicle speeds in the headup display can be set in setting mode
Normal Mode
Setting speed is saved
Press and Hold
Setting speed is not saved
(With Vehicle Stopped)
No switch operation for 10 sec.
Vehicle starts off
Setting Mode
Setting Speed (Blink)
Setting speed is saved only when the HUD main switch is pressed and held during setting mode.
Settable range is 0 to 180 km/h (0 to 199 mph).
Press and Hold
Press and Hold
Press and Hold
Press
Press
+ 1 km/h
- 1 km/h
+ 10 km/h
- 10 km/h
Instructor & Technical Staff

20. Battery Terminal Reconnection
New Model PRIUS 2009
HUD
Display Transition
Battery Terminal Reconnection
: Press and Hold
(0.8 sec. or more)
: Press
IG-ON
IG-OFF
Opening Display (3.5 sec)
IG-ON
IG-OFF
HUD ON
Setting Mode
(HUD OFF)
When the HUD OFF, the interruption displayed is not displayed.
Instructor & Technical Staff

21. Service Point (HUD) Test Mode
New Model PRIUS 2009
Service Point (HUD)
Test Mode
While test mode, the display can be inspected
: Press
Test Mode Entering Procedure
While pressing the HUD main switch, turn the power mode OFF  IG-ON  OFF  IG-ON
Start
[Test Mode Entering Procedure]
1. Turn the power mode off
2. Turn the power mode IG-ON while pressing and holding the HUD main switch
3. Keep pressing the HUD main switch and turn the power mode off
4. Keep pressing the HUD main switch and turn the power mode IG-ON
5. The headup display will show "TEST MODE"
NOTE: Turn the power mode off to finish the test mode.
Instructor & Technical Staff

22. Air Conditioner General Reference Items Contents Heater Control Panel
New Model PRIUS 2009
Air Conditioner
General
Items
Contents
Heater Control Panel
Automatic A/C
A/C Unit
Some of air is always re-circulated
Heater
SFA (Straight Flow Aluminum) -II Heater Core
PTC Heater (165 W x 3)
Electric Water Pump (for Heater and Engine Cooling)
Compressor
Scroll Type ES14 Compressor with Motor (A/C Inverter integrated)
Compressor Oil: ND11
Condenser
MF-IV Sub-cool Condenser
Evaporator
ECS (Ejector Cycle System) Evaporator
Servo Motor
Pulse Detection Type Servo Motor with Bus Connector
Blower
Brush Motor
Clean Air Filter
Pollen Removal Type
Control
Micro Dust and Pollen Filter Mode Control
Eco Mode Control
Reference
Instructor & Technical Staff

23. Air Conditioner Ejector Cycle System
New Model PRIUS 2009
Air Conditioner
Ejector Cycle System
The ejector cycle system is used in the refrigerant cycle, increasing energy consumption efficiency and cooling performance
Condenser
Expansion Valve
Ejector
Capillary Tube
ECS Evaporator
Compressor
Upwind Side
Downwind Side
Evaporator
Condenser
Expansion Valve
Compressor
Energy loss caused
by swirls
Ejector Cycle System
Conventional Cycle
Instructor & Technical Staff

24. Utilizes the energy loss as pump action Compressor Load Reduced
New Model PRIUS 2009
Air Conditioner
Ejector Cycle System
The ejector functions as a pump for the refrigerant circulation, thus reducing the compressor load
Ejector
From Evaporator (Downwind Side)
To Evaporator (Upwind Side)
From Expansion Valve
Nozzle
Mixing Portion
Diffuser Portion
Condenser
Expansion Valve
Ejector
Capillary Tube
ECS Evaporator
Compressor
Upwind Side
Downwind Side
In the conventional refrigerant cycle, a rapid pressure decrease in the expansion valve forms swirls, causing energy loss. In new ejector cycle, any lost energy can be utilized by the ejector as pump action, thus improving energy consumption efficiency.
Functions of the Ejector
- Decreases the refrigerant pressure (expands the refrigerant)
- A pump for refrigerant circulation
Reference: The construction and operation of the ejector is similar to the jet pump used in the fuel tank for some models.
Conventional Cycle
Utilizes the energy loss as pump action
Energy loss caused
by swirls
Ejector Cycle System
Compressor Load Reduced
Instructor & Technical Staff

25. Evaporator (Downwind Side) Enhanced Cooler Efficiency
New Model PRIUS 2009
Air Conditioner
Ejector Cycle System
Evaporator temp. of the downwind side can be kept lower than the upwind side, thus increasing cooling performance
Ejector
From Evaporator (Downwind Side)
To Evaporator (Upwind Side)
From Expansion Valve
Nozzle
Mixing Portion
Diffuser Portion
Condenser
Expansion Valve
Ejector
Capillary Tube
ECS Evaporator
Compressor
Upwind Side
Downwind Side
Sucked
Evaporator (Downwind Side)
The ejector operation constantly keeps the refrigerant pressure in the evaporator (upwind side) lower than the evaporator (downwind side), and creates low temperature conditions. Therefore, air cooled by the evaporator (upwind side) is further cooled by the evaporator (downwind side), thus increasing cooling performance.
Refrigerant is sucked by ejector
It keeps the refrigerant pressure lower than the evaporator (upwind side)
Air cooled by the evaporator (upwind side) is further cooled
Ejector Cycle System
Enhanced Cooler Efficiency
Instructor & Technical Staff

26. Reference (Air Conditioner)
New Model PRIUS 2009
Reference (Air Conditioner)
Ejector Cycle System
Expansion valve controls the refrigerant flow volume
Capillary tube decreases the refrigerant pressure
Condenser
Expansion Valve
Ejector
Capillary Tube
ECS Evaporator
Compressor
Upwind Side
Downwind Side
Function
Controls the refrigerant flow volume based on the evaporator outlet temp.
Feature
Construction is the same as the one used in the conventional cycle
Energy loss is greatly reduced by using the ejector
Function
Decreases the refrigerant pressure
Feature
Because the pressure decreases slowly, the energy loss is a little
Ejector Cycle System
Instructor & Technical Staff

27. (Upwind Side) (Downwind Side)
New Model PRIUS 2009
Air Conditioner
ECS (Ejector Cycle System) Evaporator
An ejector and capillary tube are included in the evaporator
Capillary Tube
Ejector
Top Tank A
An ejector is placed in the top tank of the evaporator, thus allowing the ejector cycle to operate in a space equivalent to the conventional.
A – A Cross Section
Evaporator
(Upwind Side) (Downwind Side)
Bottom Tank
ECS Evaporator
Instructor & Technical Staff

28. Air Conditioner ES14 Compressor with Motor
New Model PRIUS 2009
Air Conditioner
ES14 Compressor with Motor
The A/C inverter is integrated with the compressor
A/C Inverter
(DC  AC)
Scroll Type Compressor
DC V
Oil Separator
Brushless Motor
Caution: Never use a compressor oil other than the ND11 type
Instructor & Technical Staff

29. Air Conditioner Eco Mode Control
New Model PRIUS 2009
Air Conditioner
Eco Mode Control
The system restricts the air conditioning system performance under specified conditions, thus improving fuel economy
Eco Mode Switch
Eco Mode Indicator Light
ECO mode switch is the momentary type switch. ECO mode condition is maintained even if the power mode is turned off.
Restricts the air conditioning system performance
Instructor & Technical Staff

30. Eco Mode Control Cancel Conditions [OR]
New Model PRIUS 2009
Air Conditioner
Eco Mode Control
Operation
ECO Mode Control
Effect
Eco Mode Control Cancel Conditions [OR]
Switches the air inlet port to REC when the ambient temp. is approx. 20 °C (68 °F) or more
Reduce ventilation loss
ECO MODE switch off
DEF mode is selected*
Blower motor OFF*
Remote air conditioning system is operating*
Blower level is lowered 20 % when AUTO mode
Suppresses the power consumption
Stops PTC heater operation
Maximum speed of the compressor with motor is lowered 10 %
Decreases the engine coolant temperature to start up the engine during heating
Increases the amount of engine off time
*: Eco mode indicator light remains ON, and the Eco mode control is resumed when the cancel condition is eliminated
Instructor & Technical Staff

31. Lock Sensor (Touch Sensor)
New Model PRIUS 2009
Entry and Start System
Lock Sensor
08CY entry and start system is used
Lock switch is changed to lock sensor (touch sensor)
Lock Sensor (Touch Sensor)
Lock
NOTE: When a door is not locked even if the lock sensor is touched, touch the upper & lower side lock sensor simultaneously. It facilitates the detection of the touch operation.
NOTE:
When a door is not locked even if the lock
sensor is touched, touch the upper & lower
side lock sensor simultaneously
Instructor & Technical Staff

32. Entry and Start System System Diagram M Power Management Control ECU
New Model PRIUS 2009
Entry and Start System
System Diagram
Power Management Control ECU
Shift Lever Position Sensor
ACC Relay
IG1 Relay
Door Lock Assembly
Stop Light Switch
Courtesy Switches
IG2 Relay M
P Position Switch
SMR
Power Switch
Transponder Key Amplifier
Main Body ECU
V Bus No.1
Wireless Door Lock Buzzer
Immobiliser Code ECU
(-K, -W)
LIN
Transmission Control ECU
Combination Meter
Certification ECU
Immobiliser Code ECU Function
(-A, -Q)
Door Outside Handle (D and Fr P)
Unlock Sensor
Door Electrical Key Oscillator
Lock Sensor
Antenna
Back Door Opener Switch
Back Door Lock Switch
Electrical Key Antenna
Electrical Key Oscillators
Key
Door Control Receiver
(Indoor [Front/Center/Rear] Outside [Back Door)
Instructor & Technical Staff

33. Steering Pad Switch General
New Model PRIUS 2009
Steering Pad Switch
General
Displays the touched switch on the guide display to reduce the movement of the driver's line of sight during the steering pad switch operation
Guide Display
Touched Switch
Steering Pad Switch
Instructor & Technical Staff

34. Steering Pad Switch Steering Pad Switch
New Model PRIUS 2009
Steering Pad Switch
Steering Pad Switch
Pressure-sensitive type touch sensor is integrated to the steering pad switch A
A-A Cross-section
0.7 N
3.5 N
Free ON
0.7 N: Pressure when finger touches
Contact Spacing of Touch Sensor: 0.13 mm (0.005 in.) ON
Without Touch Sensor
Touch sensor ON
Steering Pad Switch ON
Instructor & Technical Staff

35. Steering Pad Switch Guide Display
New Model PRIUS 2009
Steering Pad Switch
Guide Display
The fuel and instant fuel consumption display areas are changed to guide display when the steering pad switch is touched ON
Touch Sensor
OFF
1 sec.
When the 2 or more switches are touched simultaneously, all touched switches are indicated on the guide display.
Guide Display
Instructor & Technical Staff

36. Steering Pad Switch Guide Display
New Model PRIUS 2009
Steering Pad Switch
Guide Display
When the touch sensor ON continued more than 20 sec., the system cancels the guide indication
Driving with involuntarily touching steering pad switch
ON stuck malfunction
etc. ON
Touch Sensor
OFF
1 sec.
When the following 2 conditions are met for more than 20 sec., the system cancels the guide indication.
- The touch sensor is ON.
- The condition of all touch sensors does not change.
When the condition of any touch sensor changes, the operation of guide display resumes.
Guide Display
20 sec.
Instructor & Technical Staff

37. Multi-information Display
New Model PRIUS 2009
Steering Pad Switch
Guide Display
Cancel function of the guide display
Multi-information Display
Setting Display
If the “STEERING SWITCH” on the multi-information display is turned off, the guide display is not displayed when the steering pad switch is touched or pressed.
Instructor & Technical Staff

38. Wire Harness Painted Wire Harness
New Model PRIUS 2009
Wire Harness
Painted Wire Harness
The vehicle wire harness uses a painted wire harness, thus reducing the kinds of harnesses
Painted
Base (Wire Color: White)
(Ex.: Red)
(Ex.: Blue)
The painted wire harness is used for the front door wire harness. The wire harness color is painted only near the terminal.
Painted only near the terminal
Front Door Wire Harness
Instructor & Technical Staff

39. * White and Gray colors are not used
New Model PRIUS 2009
Wire Harness
Painted Wire Harness
There are 2 types of paint pattern in order to distinguish easily
Color (Color Code)
Paint Pattern
Black (B)
Red (R)
Blue (L)
Green (G)
Yellow (Y)
Brown (BR)
Violet (V)
Ex.: Black / Green
White-Black (W-B)
Light Green (LG)
Pink (P)
Sky Blue (SB)
Ex.: White-Black / Light Green a
White (W) and Gray (GR) colors are not used. a
a: 3 mm (0.118 in.)
* White and Gray colors are not used
Instructor & Technical Staff