TOYOTA Hybrid Technology

TOYOTA Hybrid Technology

Contents What is the Hybrid Vehicle? THS II (TOYOTA Hybrid System)
Engine Hybrid Transaxle Inverter Assembly HV Battery THS II Operation ECB (Electronically Controlled Brake) Indicator and Warning Other System Service Point Other Hybrid Vehicles

What is the Hybrid Vehicle?

Why is the hybrid vehicle necessary? CO2 Concentration 500 300 260 600 400 (ppmv) 1200 1400 1600 1800 2000 2100 2006 1970 Increase Automobile market Expanding Energy Consumption Low fuel consumption and low CO2 emission vehicle is required

Diagnosis Technician Engine What is the Hybrid Vehicle? Why is the hybrid vehicle necessary? Hybrid technology is the core for eco-car development Ultimate eco-car Low fuel consumption Low CO2 emission THS II FCHV THS Hybrid technology is the core for eco-car development. THS: TOYOTA Hybrid System FCHV: Fuel Cell Hybrid Vehicle HV: Hybrid Vehicle DPNR: Diesel Particulate NOx Reduction DPR: Diesel Particulate active Reduction system D-4: Direct Injection 4-stroke EV: Electric Vehicle CNG: Compressed Natural Gas VVT-i: Variable Valve Timing – intelligent DPNR D-4 CNG DPR Lean Burn EV Common-rail VVT-i Alternative Energy Diesel Engine Gasoline Engine Electric Vehicle PT. TAM - TSD Training Center

Diagnosis Technician Engine What is the Hybrid Vehicle? Kind of Hybrid System Series Hybrid System In this system, the engine is used to supply electrical power to the motor, which then turns the wheels Series Hybrid System In this system, the engine is used to supply electrical power to the motor, which then turns the wheels. PT. TAM - TSD Training Center

Diagnosis Technician Engine What is the Hybrid Vehicle? Kind of Hybrid System Parallel Hybrid System The wheels are driven by both the engine and the motor Parallel Hybrid System The wheels are driven by both the engine and the motor. PT. TAM - TSD Training Center

Diagnosis Technician Engine What is the Hybrid Vehicle? Kind of Hybrid System THS (TOYOTA Hybrid System) Strong points of both series/parallel systems realized in one system THS (TOYOTA Hybrid System) Strong points of both series/parallel systems realized in one system. PT. TAM - TSD Training Center

Diagnosis Technician Engine What is the Hybrid Vehicle? THS II (TOYOTA Hybrid System) Concept Low Fuel Consumption Higher Power THS II Concept: Hybrid Synergy Drive PT. TAM - TSD Training Center

Diagnosis Technician Engine What is the Hybrid Vehicle? THS II (TOYOTA Hybrid System) Hybrid vehicle realizes low fuel consumption and higher power Good Fuel Economy PRIUS (NHW20) PRIUS (NHW11) Japanese 10 – 15 Mode Fuel Efficiency (km/L) Corolla (1.3L) Tradeoff between performance and fuel economy in conventional vehicle Hybrid vehicle realizes low fuel consumption and higher power. Corolla (1.5L) CAMRY (2.4L) Good Acceleration 0 – 100 km/h Acceleration (sec.) PT. TAM - TSD Training Center

Driving Method The vehicle can run on gasoline only, and does not need to be recharge If the battery charge drops, the engine drives the generator, which recharges the battery

Driving Method The vehicle may be driven while the “READY” light is ON The engine will stop while the vehicle is stopped, in order to improve fuel economy The engine starts up automatically after the vehicle starts off

(TOYOTA Hybrid System)
THS II (TOYOTA Hybrid System) PRIUS [NHW20]

THS II (TOYOTA Hybrid System)
Main Component Location HV Battery Inverter Engine Hybrid Transaxle Generator (MG1) Motor (MG2) Power-dividing Mechanism Click Movie

Main Component Location Shift Lever Parking Switch Shift Lever MOVIE

System Diagram Shift Position Sensor (Shift, Select) Click here to see operation of shift lever Hybrid Transaxle Electric A/C Compressor HV ECU MG1 MG2 Accelerator Pedal Position Sensor A/C Inverter Inverter EV Mode Switch Engine ECU Boost Converter DC – DC Converter Engine Skid Control ECU SMR1, 2 and 3 Brake Actuator CAN Auxiliary Battery Battery ECU Speed Sensors DLC3 HV Battery

Outline Compression from conventional vehicle Item Conventional Vehicle THS II Note for THS II Power Source Engine Motor Generator Motor drive is possible (Engine OFF) Engine motive force is divided for drive and electric generation Trans-mission A/T M/T Power Splitting Device Divide the engine, motor and generator power Function as CVT Brake Hydraulic Brake Regenerative Brake Cooperative control between hydraulic and regenerative brake Battery 12V Battery 201.6V Battery High-voltage supply for motor drive Power Train Control Engine ECU HV ECU Inverter Controls the engine, motor and generator

Outline System operation Normal Driving Start-off Acceleration Deceleration Stop Electric motor only Motor and Engine Motor and Engine (additional power drawn from battery) Battery charging Engine automatically shuts off

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) 1NZ-FXE Engine 1.5 liter, In-line 4-cylinder, 16-valve DOHC, gasoline engine 1NZ-FXE X = Atkinson Cycle [1NZ-FXE Engine] 1.5 liter, In-line 4-cylinder, 16-valve DOHC, gasoline engine X = Atkinson cycle PT. TAM - TSD Training Center

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Hybrid Transaxle Includes AC 500V motor, generator and power-dividing mechanism Uses a continuously variable transmission mechanism to achieve smooth and quiet operations MG2 MG1 Power-dividing Mechanism [Hybrid Transaxle] Includes AC 500V motor, generator and power-dividing mechanism. PT. TAM - TSD Training Center

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) HV Battery Full sealed nickel metal hydride (Ni-MH) battery DC 201.6V Located behind the rear seat [HV Battery] DC201.6 V PT. TAM - TSD Training Center

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Inverter Assembly Inverter DC  AC high voltage Variable-voltage System DC 200V stepped up to Max. DC 500V DC-DC Converter DC 200V stepped down to DC 12V A/C Inverter DC  AC to drive the A/C compressor [Inverter Assembly] Includes inverter, variable-voltage system, DC-DC converter and A/C inverter. PT. TAM - TSD Training Center

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Brake System ECB (Electrically Controlled Brake) Hydraulic brake pressure is controlled by electrical signal and cooperate regenerative brake Hydraulic Brake Control Driver’s Demand Skid Control ECU HV ECU Hydraulic brake pressure is controlled by electrical signal and cooperate regenerative brake. Regenerative Brake Control Vehicle Condition PT. TAM - TSD Training Center

Steering System EPS (Electric Power Steering) is used EPS ECU EPS Motor

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Air Conditioning System Compact, high-performance scroll compressor driven by motor Electric inverter compressor for A/C system Electric Inverter Compressor PT. TAM - TSD Training Center

Multi Display Energy Monitor

Multi Display Fuel consumption indicator

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Auxiliary Battery (12V) Auxiliary battery supplies power to headlights, audio, and all ECUs Sealed-type battery is used Auxiliary Battery Sealed- type battery is used for the auxiliary battery (12V). Notice: - Refrain from quick charging. Because the battery fluid cannot be replenished. - If the auxiliary battery needs to be replaced, replace it only with a 12V battery specially designed for the use of the PRIUS. PT. TAM - TSD Training Center

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Power Cable Orange-colored wire harness / connector High-voltage circuit High-voltage Wire Harness High-voltage wire harness and connector is orange-colored. High-voltage circuit is insulated from body ground. High-voltage Wire Harness PT. TAM - TSD Training Center

Diagnosis Technician Engine THS II (TOYOTA Hybrid System) Service Plug Shut off the high-voltage circuit Service Plug Service plug is provided to shut off the high-voltage circuit. Caution: Wear insulated gloves when disconnecting / co0nnecting the service plug to prevent against electrical shock. Caution: Wear insulated gloves when disconnecting / connecting the service plug to prevent against electrical shock PT. TAM - TSD Training Center

Engine

Diagnosis Technician Engine
Atkinson Cycle The “X” of the 1NZ-FXE indicates the use of the Atkinson cycle, the principle applied for this vehicle’s engine Atkinson cycle High thermal efficiency Atkinson cycle = High thermal efficiency 1NZ-FXE (PRIUS) PT. TAM - TSD Training Center

Overview Atkinson cycle Compression Stroke < Expansion Stroke High thermal efficiency Compression Expansion PT. TAM - TSD Training Center

Overview Atkinson cycle Depending on the driving condition, the cylinder volume is varied by VVT-i Valve Timing (Intake Valve) Cylinder Volume TDC 105º 90º 105º VVT-i Operation 72º 72º BDC PT. TAM - TSD Training Center

Overview Atkinson cycle Depending on the driving condition, the cylinder volume is varied by VVT-i Valve Timing (Intake Valve) Cylinder Volume TDC 105º 90º 105º 72º BDC PT. TAM - TSD Training Center

Overview Specifications Item 1NZ-FXE (’04 PRIUS) 1NZ-FE (Corolla) No. of Cylinders & Arrangement 4-Cylinder, in-line  Valve Mechanism 16-Valve DOHC, Chain Drive, VVT-I Displacement cm3 (cu. in.) 1497 (91.3) Bore x Stroke mm (in.) 75.0 x 84.7 (2.95 x 3.33) Compression Ratio 13.0 10.5 Max. Output EEC (-W, -Q) rpm rpm Max. Torque EEC (-W, -Q) rpm rpm Valve Timing Intake Open 18 - -15 BTDC 42 - -2 BTDC Close 72 - 105 ABDC 10 - 50 ABDC Exhaust 34 BBDC 42 BBDC 2 ATDC Emission Regulation STEP IV STEP III PT. TAM - TSD Training Center

Overview Engine compartment Drive belt simply layout TOYOTA Genuine Super LLC Radiators (for engine and inverter) are one piece PT. TAM - TSD Training Center

Overview Interior ECM is located in passenger side (LHD  right side / RHD  left side) Non-contact type accelerator pedal position sensor 32-bit engine ECU with CAN communication PT. TAM - TSD Training Center

Overview Under floor Plastic Type Fuel Tank (-W, -Q) PT. TAM - TSD Training Center

Engine Proper Piston Lightweight and low friction Piston skirt portion is reduced to friction reduction Shape is changed to weight reduction 223g (Corolla)  194g (Prius) Prius Corolla New resin coat: improve wear resistance of resin coat New resin coat to friction reduction PT. TAM - TSD Training Center

Engine Proper Piston Ring Lower tension and thinner piston ring is used for friction reduction Piston Ring Cross section Tension Thickness Others Top Ring Inner Bevel Type 4.2 N  3 N 1.2 mm (0.047 in.) 0.8 mm (0.031 in.) PVD coat is used to improve wear resistance Second Ring Taper Type 3.3 N 1.0 mm (0.039 in.) Steel material is used to improve wear resistance Oil Ring 2 Piece Type 17 N 8 N 2.0 mm (0.079 in.) 1.5 mm (0.059 in.) - Corolla  Prius PT. TAM - TSD Training Center

Throttle Body (ETCS-i) Throttle valve is controlled by the HV ECU. ETCS-i also controls the cruise control system. PT. TAM - TSD Training Center

Cooling System Radiators (for engine and inverter) are one piece Front Radiator (for engine) Drain Plug (for engine) Radiator (for Inverter) PT. TAM - TSD Training Center

Coolant Heat Storage System General This system reduces the amount of adhesion of fuel on the intake port wall after engine starting Before engine start Hot coolant in the tank Amount of adhesion of fuel is reduced after engine start The coolant heat storage system recovers the engine coolant that has been heated by the engine and stores it in the coolant heat storage tank. Then, the system supplies the hot coolant to the engine before starting a cold engine, in order to preheat the intake port of the engine. This effectively reduces the fuel injection volume during cold starting, minimizes the adhesion of fuel onto the intake port wall surface, and reduces HC exhaust emissions. -A SPEC. only Hot coolant to cylinder head Heated PT. TAM - TSD Training Center

Coolant Heat Storage System Components to / from heater core Engine Coolant Temp. Sensor Water Pump (for Heater) Coolant Heat Storage Water Pump Water Valve This system consists primarily of a coolant heat storage tank, coolant heat storage water pump, water valve, coolant heat storage tank outlet temperature sensor and ECM. Engine Coolant Capacity: 8.6 Liters (9.09 US qts., 7.57 Imp qts.) Coolant Heat Storage Tank Coolant Heat Storage Tank Outlet Temp. Sensor Reverse Side PT. TAM - TSD Training Center

Coolant Heat Storage System Operation Engine running (w/o storage operation) Heater Core Cylinder Head Water Valve Water Pump Water Pump Cylinder Block OFF PT. TAM - TSD Training Center

Coolant Heat Storage System Operation Storage operation (during engine running) Heater Core Cylinder Head Water Valve Water Pump start condition  engine coolant temp. reaches the specified value stop condition  Tank coolant temp. reaches the specified value for details, see the reference page Water Pump Cylinder Block OFF Hot coolant is stored PT. TAM - TSD Training Center

Confidential Coolant Heat Storage System Operation Storage operation (during engine running) Operation chart Tank coolant temp. is 90 °C (194 °F) or more Engine Starting Warm-up Storage is Completed Others Meets start conditions Meets stop conditions Storage operation is a maximum of 4 times  To secure the durability of the water valve Storage operation (during engine running) [Max.: 4 times] PT. TAM - TSD Training Center

Coolant Heat Storage System Diagnosis DTCs for Coolant Heat Storage System DTC No. Detection Item P1115 Coolant temp. sensor circuit for coolant heat storage system P1122 Water valve position sensor circuit low P1116 Coolant temp. sensor circuit stuck for coolant heat storage system P1123 Water valve position sensor circuit high P1117 Coolant temp. sensor circuit low for coolant heat storage system P1150 Coolant Path Clog Up for Coolant Heat Storage System P1118 Coolant temp. sensor circuit high for coolant heat storage system P1151 Coolant Heat Storage Tank P1120 Water valve position sensor circuit P2601 Coolant pump control circuit range / performance P1121 Water valve position sensor circuit stuck P2610 ECM / PCM internal engine off timer performance PT. TAM - TSD Training Center

Coolant Heat Storage System Service Point Coolant Replacement Drain engine coolant Caution: The coolant in coolant heat storage tank is hot even if engine and radiator are cold Disconnect the coolant heat storage water pump connector Remove the radiator cap Connect a vinyl hose to drain cocks (engine, radiator, coolant heat storage tank) Loosen the drain cock plugs (engine, radiator, coolant heat storage tank), and drain coolant Drain the coolant in the radiator reservoir tank PT. TAM - TSD Training Center

Coolant Heat Storage System Service Point Coolant Replacement Fill engine coolant Tighten the drain cock plugs and disconnect a vinyl hose (engine, radiator, coolant heat storage tank) Connect a vinyl hose to the bleeder plug of radiator and insert the another side of hose to reservoir tank Using 6 mm socket hexagon wrench, loosen the radiator bleeder plug from service hole Fill the coolant into the radiator Tighten the radiator bleeder plug and install the radiator cap Fill the radiator reservoir tank with coolant to the full level Connect the coolant heat storage water pump connector Connect the Intelligent Tester II to DLC3 and turn to IG/ON PT. TAM - TSD Training Center

Coolant Heat Storage System Service Point Coolant Replacement Fill engine coolant Perform the ACTIVE TEST of water pump (coolant heat storage water pump operates for 30 sec.) Loosen the radiator bleeder plug and fill the coolant into the radiator Tighten the radiator bleeder plug Repeat the steps 9 to 11 until coolant cannot be added Disconnect the vinyl hose Warm-up engine until the thermostat is opened (inspection mode) Stop the engine, and wait until the coolant gets cold Fill the coolant into the radiator Repeat the step 14 to 16 until coolant level stops going down Check DTC and clear the DTC which relates to the water pump PT. TAM - TSD Training Center

Fuel System (Vapor reducing fuel tank) Reduce the amount of fuel vapors released when vehicle is parked. The vapor reducing fuel tank system, which reduces the amount of fuel vapor generated when the vehicle is parked, during refueling, or while driving. This system provides a vapor reducing fuel tank that expands or contracts in accordance with the volume of the fuel in the fuel storage area in the fuel tank. By thus reducing the space in which fuel can evaporate, the generation of fuel vapor is minimized. PT. TAM - TSD Training Center

Fuel System (Vapor reducing fuel tank) It is composed of two parts: a metal outer tank, and a plastic membrane inside the fuel tank. NOTE: Normal tank capacity is 45 liters; tank capacity decreases by 5 liters at –10°C. Click! zoom PT. TAM - TSD Training Center

Inner Tank Outer Tank Click! Back PT. TAM - TSD Training Center

Fuel System (Vapor reducing fuel tank) Fuel Sender Gauge Sub-tank is installed inside the fuel tank, inside which a fuel pump and sender gauge are attached. Sub-tank Fuel Sender Gauge PT. TAM - TSD Training Center

Fuel System (Vapor reducing fuel tank) Fuel Sender Gauge The fuel pump and sender gauge can not be removed from the fuel tank. If the pump or gauge malfunctions Replace the tank assembly PT. TAM - TSD Training Center

Drive Belt System A/C compressor pulley is not existing Simply belt layout Adjust Bolt Idler Pulley Water Pump Pulley Crank Pulley A/C compressor pulley is not existing PT. TAM - TSD Training Center

Hybrid Transaxle

Hybrid Transaxle Overview P112 type Components: MG (Motor Generator) 1
Power-dividing Mechanism (Planetary Gears) Reduction Mechanism Differential Mechanism Fluid type: ATF WS Capacity: 3.8 liters

Hybrid Transaxle Overview P112 type Chain-drive Sprocket
Planetary Gears MG2 MG1

Hybrid Transaxle Overview P112 type Counter Drive Gear
Chain-driven Sprocket Counter-driven Gear Reduction Mechanism Final Drive Pinion Gear Final Ring Gear Differential Mechanism

Hybrid Transaxle MG1 / MG2
Compact and lightweight, highly efficient AC500V motor generator MG2 MG1

Hybrid Transaxle MG1 Main operations  Generator
When engine starting  Starter Stator Coil MG1 Rotor Speed Sensor

Hybrid Transaxle MG2 When driving  Main power to engine power (Starting off) or provides supplementary When braking  Converts kinetic energy to electrical energy MG2 Stator Coil Rotor Speed Sensor

Hybrid Transaxle Speed Sensor (Resolver) Detects position, speed and direction of MG1 / MG2 rotors Speed Sensor (for MG2) Speed Sensor (for MG1) MG1 and MG2 has speed sensor (resolver). PT. TAM - TSD Training Center

Hybrid Transaxle Transaxle Damper
Installed at location of conventional clutch Reduces shock which occurs when kinetic energy is transmitted

Hybrid Transaxle Cooling System Cooling circuit is used for both MG1 / MG2 Separate cooling system from engine Reservoir Pump MG1 / 2 Radiator Inverter Reservoir Tank Coolant Type: SLLC Coolant maintenance schedule is same as engine coolant. Electric Water Pump Radiator PT. TAM - TSD Training Center

Hybrid Transaxle Oil Pump Forced lubrication system via trochoid pump used to lubricate main shaft bearings Oil pump functions when engine is being driven Oil Pump Oil pump driven by engine. PT. TAM - TSD Training Center

Hybrid Transaxle Mayor Different with Prius Generation III Oil pump driven by engine. PT. TAM - TSD Training Center

Inverter Assembly

Inverter Assembly Components Inverter DC  AC high voltage Variable-voltage System DC201.6V stepped up to max. DC500V DC-DC Converter DC201.6V stepped down to DC 12V A/C Inverter DC  AC to drives the A/C compressor Components: - Inverter: Converts DC to AC (AC to DC) - Variable-voltage system: DC201.6 stepped up to max. DC500V - DC-DC converter: DC201.6 stepped down to DC12V - A/C inverter: Converts DC to AC to drive electric inverter compressor PT. TAM - TSD Training Center

Variable-voltage System
Inverter Assembly Components Inverter Assembly MG1 Inverter Variable-voltage System MG2 HV Battery A/C Inverter DC - DC Converter

Inverter Assembly Variable-voltage System DC 201.6V  Max. DC 500V conversion Max. DC 500V   DC 201.6V Inverter Assembly Inverter (IPM) MG1 Variable-voltage System IPM (IGBT) Reactor DC 201.6V DC500V AC500V Variable-voltage System uses IGBT(Insulated Gate Bipolar Transistor = semiconductor switching device) and the reactor to boosts voltage. This device is 20% smaller than the similar device used in THS (’03 model) and has achieved low heat generation and high efficiency. MG2 HV Battery : Discharge : Charge PT. TAM - TSD Training Center

Inverter Assembly Inverter Operation Motor control Motor Torque is controlled by the current value Motor Speed is controlled by the frequency High Speed High Torque Motor Torque is controlled by the current value. Motor Speed is controlled by the frequency. Low Torque Low Speed PT. TAM - TSD Training Center

Inverter Assembly DC – DC Converter DC201V  DC 12V Inverter Assembly HV Battery MG1 Variable-voltage System Inverter MG2 DC – DC Converter DC201.6V to DC12V conversion to charge the auxiliary battery. DC  AC AC 201.6V  AC 12V AC  DC DC 12V DC 201.6V Auxiliary Battery PT. TAM - TSD Training Center

Inverter Assembly A/C inverter DC201.6V  AC201.6V conversion A/C ECU HV ECU DC 201.6V  AC 201.6V Target Compressor Speed AC 201.6V DC 201.6V to AC 201.6V conversion to supplies the AC voltage to electric inverter compressor. DC 201.6V A/C Inverter HV Battery Electric Inverter Compressor Inverter Assembly PT. TAM - TSD Training Center

Inverter Assembly Cooling System Cooling circuit is used for inverter assembly Separate cooling system from engine Reservoir Pump MG1 / 2 Radiator Inverter Reservoir Tank Coolant Type: SLLC Coolant maintenance schedule is same as engine coolant. Electric Water Pump Radiator PT. TAM - TSD Training Center

HV Battery Assembly

HV Battery Assembly Power Supply The HV battery supplies power to MG1 / MG2 The auxiliary battery supplies power to HV ECU and Engine ECU (all ECU) When both are functioning properly, the vehicle will start 2 types of battery. - HV battery (DC201.6V) - Auxiliary battery (DC12V) HV Battery (DC 201.6V) Auxiliary Battery (DC 12V) PT. TAM - TSD Training Center

Service Plug Connector
HV Battery Assembly Components Module Current Sensor Battery ECU SMR3 SMR2 SMR1 Service Plug Connector Resister

HV Battery Assembly Battery Module Nickel metal hydride (Ni-MH) battery (1.2V x 6 cells) x 28 modules = 168 cells = DC V 28 Module (1.2V x 6 cells) x 28 modules = 168 cells x 1.2V = DC V Module (1.2V x 6 cells) PT. TAM - TSD Training Center

HV Battery Assembly Battery ECU
Maintains control of HV battery SOC (State of charge) Ensures battery capability Battery ECU CAN SOC Control Cooling Fan Control Electrical Leakage Detection for High-voltage System Diagnosis Function for HV Battery HV Battery Condition Detection Battery Cooling Fan Relay HV ECU Engine ECU A/C ECU Battery Cooling Fan Controller Voltage x 14 Temp. x 4 + Temp. Sensors (Thermistor) Service Plug Battery Cooling Fan Motor - Current Sensor HV Battery

HV Battery Assembly Battery ECU Controls SOC to match THS characteristics The SOC is maintained at approx, 60%. A margin is given for further recharging via regenerative braking Sends requests to HV ECU to obtain desired SOC SOC (State Of Charge) PT. TAM - TSD Training Center

HV Battery Assembly SOC Control
When the SOC is dropped, battery ECU sends the “Charge Request” signal to HV ECU Battery ECU Charge Request Power Request HV ECU Engine ECU SOC Control Voltage (SOC) Charging Charge MG1 Drive HV Battery Engine

HV Battery Assembly SMR (System Main Relay) Turns ON / OFF the high-voltage circuit SMR3 SMR1 SMR turns ON / OFF the high-voltage circuit. SMR2 PT. TAM - TSD Training Center

HV Battery Assembly SMR Shutdown control READY OFF At Collision When one of the following conditions occurs, HV ECU shutdowns the SMR. - Ready OFF operation is done by the driver. - The vehicle collided. - Inter lock switch is OFF. (service plug grip disconnection, inverter cover open) Interlock Switch OFF (Service plug grip disconnection, Inverter cover open) PT. TAM - TSD Training Center

HV Battery Assembly Service Plug Shut off the high voltage circuit manually Service Plug Service plug shuts off the high voltage circuit manually. PT. TAM - TSD Training Center

HV Battery Assembly Auxiliary Battery Auxiliary battery supplies power to headlights, audio, and all ECUs Auxiliary Battery Auxiliary battery (12V) supplies power to headlights, audio, and all ECUs. It is located at the luggage compartment. PT. TAM - TSD Training Center

HV Battery Assembly Auxiliary Battery Sealed-type battery is used Notice: Refrain from quick charging Because the battery fluid cannot be replenished Never use an ordinary battery Sealed-type battery is used. Notice: Refrain from quick charging. Because the battery fluid cannot be replenished. If the auxiliary battery needs to be replaced, replace it only with a 12V battery specially designed for the use of the PRIUS. PT. TAM - TSD Training Center

HV Battery Assembly Auxiliary Battery Jump Start Terminal ”+” terminal of auxiliary battery for jump start is used Jump Start Terminal ”+” terminal of auxiliary battery for jump start is used at the relay block. PT. TAM - TSD Training Center

Special Notes on Service
Diagnosis Technician Engine Special Notes on Service Auxiliary Battery Jump Start Procedure Auxiliary Battery Negative Terminal Positive Terminal Click Movie PT. TAM - TSD Training Center

THS II Operation

THS II Operation Components HV Battery Generator (MG1) Engine Inverter
Power-dividing Device Motor (MG2) Differential Mechanism

Power-dividing Mechanism
THS II Operation Power-dividing Mechanism (Planetary Gears) Sun gear: MG1 Planetary Carrier: Engine Ring Gear: MG2 (Front Wheel) MG2 Engine MG1 Power-dividing Mechanism Chain To Front Wheel

THS II Operation Engine Starting and Idling Vehicle Speed Click!
animasi Click! Movie

THS II Operation Vehicle Starting Off Vehicle Speed Click! Click!

THS II Operation Accelerating Under Low Load (Light Throttle)
Request more power, MG1 starts engine Vehicle Speed Click! animasi Click! Movie

THS II Operation Accelerating Under Heavy Load (Full Throttle)
Vehicle Speed Click! animasi Click! Movie

THS II Operation Decelerating Vehicle Speed Click! Click! animasi
Movie

THS II Operation Driving in Reverse Vehicle Speed Click! Click!

THS II Operation THS-II Control Motive Force Suppression Control When wheel slipping is detected, the HV ECU controls the MG2 motive force and applies the hydraulic brake force Each wheel Speed Sensors Slipping Skid Control ECU HV ECU High Speed Traction Control [Motive Force Suppression Control] Main control >>> MG2 motive force control Sub control >>> hydraulic brake control [Hydraulic Brake control] Slipping at one side >>> brake is applied for the slipping wheel in order to secure the driving force Slipping at front wheels >>> brake is not applied (MG2 motive force control only) Speed Sensor MG2 Brake Force Inverter PT. TAM - TSD Training Center

THS II Operation THS-II Control Motor Drive Mode Control (except U.S.A. model) In this mode, the vehicle is driven by only MG2 by operating the EV Mode Switch EV Mode Switch HV ECU Engine ECU Combination Meter Battery ECU SOC Condition Battery Temp. EV Mode Indicator Light Gateway ECU HV Battery In the motor drive mode, the vehicle is driven by only MG2. Accelerator Pedal Position Sensor Drive Inverter Speed Sensors Skid Control ECU PT. TAM - TSD Training Center

THS II Operation THS-II Control
Motor Drive Mode Control (except U.S.A. model) EV Mode Switch is momentary type EV Mode Switch LHD Model

THS II Operation THS-II Control Motor Drive Mode Control (except U.S.A. model) Operation conditions Push Normal EV Mode EV mode canceling conditions EV mode switch is pushed HV battery SOC drops HV battery temp. is low or high Engine is warming up Vehicle speed exceeds the specified speed The accelerator pedal position angle exceeds the specified value Reference: The motor drive mode will become off after running for approx. 1 km (0.6 mile) at less than 45 km/h (28 mph) of a level load successively with the standard SOC of the HV battery or PT. TAM - TSD Training Center

(Electronically Controlled Brake)
ECB (Electronically Controlled Brake)

ECB (Electronically Controlled Brake)
Diagnosis Technician Engine ECB (Electronically Controlled Brake) General The total brake force provided by both hydraulic and regenerative brakes matches the braking power required The total brake force provided by both hydraulic and regenerative brakes matches the braking power required. Regenerative Brake Hydraulic Brake PT. TAM - TSD Training Center

ECB (Electronically Controlled Brake)
Diagnosis Technician Engine ECB (Electronically Controlled Brake) ECB Operation Hydraulic brake pressure is generated electrically (brake by wire) ECB Vehicle Brake Force Generation Skid Control ECU Control Sensor Conventional Vehicle Brake Force Generation PT. TAM - TSD Training Center

Indicator and Warning

Indicator and Warning Combination Meter READY light indicates that the vehicle is ready to drive Ready Light READY light indicates that the vehicle is ready to drive. PT. TAM - TSD Training Center

Indicator and Warning Multi Display Energy monitor shows the energy flow Energy monitor is displayed on multi display. PT. TAM - TSD Training Center

Indicator and Warning Multi Display Warning display Warning marks High Engine Coolant Temperature Warning Oil Pressure Warning Discharge Warning EPS Warning Automatic Headlight Leveling System Warning Hybrid System Abnormal HV Battery Warning Discharge warning light: Turns ON when malfunction is detected in 12V charge system (DC-DC Converter). Hybrid system warning light: There is a malfunction in hybrid system. HV battery warning light: SOC: Lights when the HV battery is discharged to the lower limit. Note: The master warning light lights up when the some warning mark appears on the multi display. PT. TAM - TSD Training Center

Indicator and Warning Multi Display Warning message When parking for long time while READY indicator is on, change shift lever to P position, because HV battery can not be recharged at N position. PT. TAM - TSD Training Center

Other Systems

Other Systems General Engine is operated intermittently, so power steering and A/C compressor uses electric power Engine is operated intermittently, so power steering and A/C compressor uses electric power. EPS (Electric Power Steering) Electric Inverter Compressor PT. TAM - TSD Training Center

Other Systems EPS (Electric Power Steering) Column assist type EPS is used EPS ECU DC Motor (12V) Basic construction and operation is same as COROLLA (NZE121). Reduction Mechanism Torque Sensor Column Assist Type EPS PT. TAM - TSD Training Center

Other Systems Air Conditioning Service Point Don’t use the compressor oil other than ND11 ND-OIL11 ND-OIL8 Don’t use the compressor oil other than ND11. Because the motor is used in the electric inverter Compressor, the ND11 oil with high electric insulation performance is used. If ND8, ND9 or other oil is mixed in A/C cycle, the electric insulation performance extremely drops. (There is possibility of electric leakage) PT. TAM - TSD Training Center

Service Point

Service Point Inspection Mode In the inspection mode, engine is continuously operated (P range) and motor TRC is turned off Mode Vehicle Condition Purpose Transferring Procedure Inspection Mode-2WD Inspection (Inspection Mod1) Keeps engine running (P range) Motor TRC is OFF Exhaust gas test Engine adjusting Speedometer test Manual procedure Intelligent tester (Active Test) Inspection Mode-2WD Chassis-Dynamo (Inspection Mod2) Speedometer test (chassis dynamometer) Inspection Mode - Engine will always run when shift lever is set to P. - Motor traction control is turned off. Inspection mode is used to the following cases: - Engine adjusting - Exhaust gas testing - Speedometer testing Note: If the accelerator pedal is depressed >>> Engine speed: rpm. Notice: Traveling on a road without resetting the inspection mode may damage the transaxle. Note: Other hybrid vehicle has several types of inspection mode. For derails, please refer to the repair manual. PT. TAM - TSD Training Center

Service Point Inspection Mode Manual procedure within 60 seconds with brake Accelerator Pedal [Transfer to the Inspection Mode (Manual Procedure)] Note: Perform the following steps in order within 60 seconds. 1. Change the power mode from OFF to IG-ON. 2. In P position, depress the accelerator pedal twice. 3. In N position (with brake pedal depressing), depress the accelerator pedal twice. 4. In P position, depress the accelerator pedal twice. 5. Change the power mode to READY for continuous engine operations. Note: In the inspection mode, engine is continuously operated (P range) and motor TRC is turned off. To cancel the inspection mode, turn off the power mode. OFF  IG-ON IG-ON  READY Depress twice Depress twice Depress twice Change the power mode to OFF  inspection mode is canceled Click Movie PT. TAM - TSD Training Center

Service Point High-voltage Wire Harness All high-voltage wire harness and connectors are colored orange High-voltage Wire Harness All high-voltage wire harness and connectors are colored orange. High-voltage Wire Harness Click Movie PT. TAM - TSD Training Center

Service Point High-voltage Wire Harness Use a megohmmeter to measure the insulation resistance (Standard: 2  10 M) It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester When you check the insulation resistance, use a megohmmeter. Basically use the 500V range. Notice: If you use the 1000V range, it causes the breakdown of the parts. Note: It cannot check the insulation resistance correctly by the TOYOTA Electrical Tester. Because the insulation resistance is very high. Standard Value of Insulation Resistance: 2 – 10 M or higher (standard value is different depending on the measurement position) Megohmmeter Basically use the 500V range Notice: If you use the 1000V range, it causes the breakdown of the parts PT. TAM - TSD Training Center

Service Point High-voltage Wire Harness Risk of electric shock Case Condition Risk of Electric Shock Touch the high-voltage + side No risk Touch the body (high-voltage - side) when there is a electrical leakage Touch the high-voltage + side when there is a electrical leakage Possibility of electric shock Touch the high-voltage + and - side Electric shock ! PT. TAM - TSD Training Center

Service Point Safety Precautions Before servicing the high voltage area Make sure to perform the followings; 1. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign 2. Turn the power mode to off 3. Remove the key from key slot and carry the key 4. Disconnect auxiliary battery negative terminal 5. Check the insulated gloves 6. Remove the service plug 7. Wait 5 min. or more 8. Measure the inverter terminal voltage (0V check) When servicing the high voltage area, make sure to perform the followings; 1. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign. 2. Turn the power mode to off. 3. Remove the key from key slot and carry the key. 4. Disconnect auxiliary battery negative terminal. 5. Check the insulated gloves. 6. Remove the service plug. 7. Wait 5 min. or more. 8. Measure the inverter terminal voltage (0V check). PT. TAM - TSD Training Center

Service Point Safety Precautions 5. Before servicing the high voltage area Wait 10 minutes or more to discharge high-voltage condenser in the inverter 5 min. High-voltage Condenser Discharge Service plug disconnection Elect-ricity 0V Inverter Assembly After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals. Note: 5 minutes are required to discharge the high-voltage condenser inside the inverter assembly. PT. TAM - TSD Training Center

Service Point Safety Precautions Before servicing the high voltage area 1.Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high-voltage system is being inspected and/or repaired. PT. TAM - TSD Training Center

Service Point Safety Precautions Before servicing the high voltage area 5.Check the insulated gloves Not cracked, ruptured, torn, or damaged Insulated glove - not cracked, ruptured, torn, or damaged - not wet Not wet PT. TAM - TSD Training Center

Service Point Safety Precautions Before servicing the high voltage area 6.Remove the service plug Carry in your pocket Service Plug Before inspecting or servicing the high-voltage system, remove service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while you are servicing the vehicle. Remove before servicing PT. TAM - TSD Training Center

Service Point Safety Precautions Before servicing the high voltage area 8.Measure the inverter terminal voltage (0V check) 0 V Between 3 phases 3 phases and body ground Using a voltmeter, measure the voltage between terminals of 3 phases (U-V, V-W, U-W) and between each terminal and body ground to verify that they are approx. 0V. Caution: Wear the insulated gloves. 0 V Inverter Assembly PT. TAM - TSD Training Center

Service Point Safety Precautions During servicing the high voltage area Insulate the tools by vinyl tape Insulated Vinyl Tape PT. TAM - TSD Training Center

Service Point Safety Precautions During servicing the high voltage area Insulate the disconnected high-voltage connector with insulated vinyl tape Insulated Vinyl Tape After disconnecting a high-voltage connector or terminal, insulate it with insulated vinyl tape. PT. TAM - TSD Training Center

Service Point Safety Precautions During servicing the high voltage area Non-reusable nut is used to the installation of high voltage line New Example of use Wire x SMR Non-reusable nut is used to the installation of high voltage line. Used Non-reusable Junction Block x Module PT. TAM - TSD Training Center

Service Point Safety Precautions After servicing the high voltage area Before reinstalling the service plug, check again the following You have not left a part or tool inside The high-voltage terminal nuts and screws are properly tightened The connectors are correctly connected Before reinstalling the service plug, check again that - you have not left a part or tool inside. - the high-voltage terminal screws are properly tightened. - the connectors are correctly connected. PT. TAM - TSD Training Center

Service Point Safety Precautions After servicing the high voltage area Be sure to install the service plug before starting the hybrid system Vehicle damages After servicing Be sure to install the service plug before starting the hybrid system. Starting the hybrid system with the service plug removed may damage the vehicle. Installation READY ON PT. TAM - TSD Training Center

Service Point Response When The HV Battery (201.6V) Runs Out Vehicle conditions when HV battery low voltage HV Battery Warning Light illuminates Can not READY ON DTC P (HV Battery Malfunction) is detected PT. TAM - TSD Training Center

Service Point Response When The HV Battery (201.6V) Runs Out Charge the HV Battery using THS Charger When the HV battery runs out, charge it by THS Charger. Charging time for engine start: Approx. 10 minute (at 25°C) Caution: Wear the insulated gloves when connect / disconnect the THS charger. Never disconnect the THS charger connecter during charging. THS Charger THS Charger Note: THS charger is the recommended tool PT. TAM - TSD Training Center

Service Point Battery Pack Removal / Installation If the HV battery electrolyte leaks, don’t touch it Neutralize battery electrolyte Don’t touch the battery electrolyte ! Boric Acid Solution [Caution at battery pack removal] - The HV battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. - To neutralize battery electrolyte, use a boric acid solution or vinegar. Boric Acid (800 g) Water (20 liters) PT. TAM - TSD Training Center

Service Point Towing Notice: If there is a electrical leakage, motor regenerates the electricity by wheel rotation PT. TAM - TSD Training Center

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