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Welcome
Course Agenda
Day One
Hybrid System Overview
Transaxle Operation
Day Two
High Voltage System
Engine
Day Three
Brake System
Electric Power Steering
Air Conditioning
Multiplex Communication
Hybrid General Maintenance
071 Toyota Hybrid System
Worksheet Overview
Worksheet 1: Hybrid Walkarounds
Worksheet 2: Data List Test Drive
ILD 1: Transaxle Assembly Parts Identification
ILD 2: Inverter Safety
ILD 3: Battery Safety
Worksheet 3: High Voltage System
Worksheet 4: HV Battery State of Charge
ILD 4: Highlander Hybrid EPS on Pico Scope
Worksheet 5: Techstream (Hybrid EPS Initialization,
Electric Air Conditioning System)
Hybrid System
Overview
Toyota is the
world leader in
hybrid technology.
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purpose is to create an extra page for handbook text.
HV Battery
Inverter
Hybrid Transaxle
Motor / Generator 1
Motor / Generator 2
071 Toyota Hybrid System
HV Battery
Engine
01 03 Prius1NZ-FXE (1.5L)
04 09 Prius.1NZ-FXE (1.5L)
10 up Prius2ZR-FXE (1.8L)
Highlander HV3MZ-FE (3.3L)
Camry HV....2AZ-FXE (2.4L)
10
Inverter
Controls current to
motor generators
Also provides correct
voltages to other
systems.
11
HV Battery
Stores electrical
energy to drive
the system
12
13
14
READY
15
Starting Out
16
Engine Starting
17
Light Acceleration
18
19
Full Acceleration
20
Deceleration
21
Reverse
22
23
ACC
IG-ON
OFF
READY
Vehicles enters
READY mode
24
Worksheet 1
Walkaround
25
Worksheet 2
Test Drive
26
Warning Lights
04 09 Prius
READY Light
Low
temperature
indicator
light
27
28
Transaxle
Operation
29
Hybrid Transaxle
01 03 Prius
Silent Chain
MG2
MG1
Transaxle Damper
30
Construction of MG1
Stator Coil
Rotor
01 03 Prius
Resolver
071 Toyota Hybrid System
31
Construction of MG2
01 03 Prius
Stator Coil
Rotor
Resolver
071 Toyota Hybrid System
32
Motor/Generators
2010 Prius
MG1
MG2
P112
071 Toyota Hybrid System
P410
33
Construction of MGR
Highlander Hybrid
Resolver
Stator
Rotor
34
Stator
Coil A
Coil B
Rotor
Coil C
Output
Side
35
36
MG2
Oil Pump
(Mechanical)
Transaxle Damper
MG1
Final Drive Gear
Final Driven Gear
Counter Driven Gear
Differential Gear Unit
071 Toyota Hybrid System
37
Power Split
Planetary Gear Unit
Motor Speed
Reduction Planetary
Gear Unit
38
MG2
Engine
Ring Gear
Carrier
Counter
Driven Gear
(To Wheels)
39
Transaxle Damper
2010 Prius
Torque limiter
Coil spring
Transaxle Damper
40
Filler Plug
(for ATF)
Adopts a shift
control actuator
Oil pan is
discontinued & WS
type ATF is used
Drain Plug
(for Coolant)
Drain Plug
(for ATF)
41
Fluid Type
Capacity
WS
3.5 qts
Maintenance Interval
(initial)
100,000 miles
Maintenance Interval
(subsequent)
50,000 miles
42
0 to 0.20
in.
43
HV
ECU
Engine
ECU
(ECM)
BEAN
Combination
Meter
44
Select Sensor
Shift Sensor
45
Cycloid Reduction
Mechanism
Stator &
Coil
Rotor
Rotation Angle
Sensor
46
Hybrid Transaxle
Parking Switch
Shift Control
Actuator
Request
HV ECU
P or Not P
T/M
Control
ECU
Parking Lock
Mechanism
Control
Position
Shift Lever
47
Service Tip
04 09 Prius
To solve this
problem, stop the
vehicle
and apply
the parking
brake.
This will bypass the problem, allowing the vehicle to shut down.
48
Drive Modes
2010 Prius
ECO MODE
EV Mode
Driving with only the electric motor
PWR MODE
Optimizes acceleration performance
by increasing the motive force in
relation to accelerator pedal operation
Normal
Motive Force Output
PWR
Mode
ECO
Mode
49
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purpose is to create an extra page for handbook text.
50
Shift to N range
Lock Piece
Slider
Shift Cable
51
52
53
High Voltage
System
54
55
56
HV Battery
Inverter
Auxiliary
Battery
A/C Compressor
Engine Room
Junction Block
Auxiliary
Battery
Inverter
Engine Room
Junction Block
HV Battery
2004-2009 Prius
2001-2003 Prius
Junction Block
A/C Compressor
HV Battery
Inverter
2010-up Prius
071 Toyota Hybrid System
57
HV Relay Assembly
Rear Drive
Unit (MGR)
Inverter
Assembly
HV Battery
Highlander Hybrid
A/C Compressor
Inverter
Assembly
Camry Hybrid
HV Battery
DC-DC Converter
071 Toyota Hybrid System
58
HV Battery
59
Highlander Hybrid
288 VDC
Camry Hybrid
245 VDC
60
HV Battery - Layout
01 03 Prius
Battery ECU
SMR (System Main Relay)
HV Battery Module
61
HV Battery - Layout
04 09 Prius
HV Battery
Module
SMR 3
SMR 2
Battery ECU
SMR 1
62
HV Battery - Components
2010 Prius
Temperature Sensors
(for battery modules)
HV Battery
(Battery Modules)
Battery Smart
Unit
HV Battery
Cooling Blower
HV Junction
Block Assembly
HV Battery
Temperature Sensor
(for intake air)
CAUTION: The HV battery is a high-voltage component that only Certified Hybrid Technicians
should service.
071 Toyota Hybrid System
63
Overcharged region
Control
region
SOC
Undercharged region
Time
Lower SOC
control limit
64
Battery
Smart Unit
SMRG
SMRB
HV Battery
Power Management
Control ECU (HV CPU)
Current Senor
SMRP
Resistor
Service
Plug
Battery Modules
SMRB
SMRG
HV Battery
Current Sensor
SMRP
Precharge
Resistor
65
SMR Control
SMR2
(+) to Inverter
Resistor
SMR1
Service Plug
HighVoltage
Fuse
SMR3
(-) to Inverter
GND
071 Toyota Hybrid System
to THS ECU
66
2001-2003
Prius
2004-2009
Prius
2010-up
Prius
67
HV Battery Cooling
2007-2010
Camry Hybrid
2006-2007
Highlander Hybrid
071 Toyota Hybrid System
68
Inverter
69
Inverter Assembly
Highlander Hybrid
HSD Inverter
MG ECU
Controls inverter
components
Boost Converter
288 VDC - 650 VDC
Inverter
AC - DC
DC-DC Converter
288 VDC - 12 VDC
70
Front
Back
71
Safety Steps
72
73
Preparation
74
613
614
DC High-voltage Area
75
76
Low Voltage
High Voltage
00
500
7,500
1,000
17,000
26,500
36,000
77
78
79
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purpose is to create an extra page for handbook text.
80
81
82
1.
2.
3.
4.
83
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purpose is to create an extra page for handbook text.
84
85
86
Service Plug
Removal
87
Service Plugs
1
2
Protective Cover
88
89
High-voltage Condensers
Dis
cha
rge
Electricity
0V
MODEL
Discharge
WAIT TIME from Service
Plug Removal
2001-2009 Prius
5 minutes
2010-up Prius
10 minutes
Highlander Hybrid
5 minutes
Camry Hybrid
10 minutes
Time
90
91
During HV Repair
92
93
Insulating Connectors
CAUTION:
Do not touch any bare cables that may have high-voltage.
Cover disconnected high-voltage connectors with insulating
vinyl tape
94
Chemical Hazards
Highlander Hybrid
Dont touch!
95
96
New Nut
Old Nut
97
98
04 09 Prius HV
Battery, 10 Prius HV
Battery, Camry HV
Battery, Highlander HV
Battery Assembly & Parts
Identification
99
After HV Repair
100
After
Repair
START
Installation
Hydrogen
Vent Hose
101
1
2
2
1
Click is
heard
102
103
Worksheet 3 & 4
HV Systems
State of Charge (SOC)
104
105
Engine
2ZR-FXE
01 09 Prius:
1NZ-FXE
Highlander Hybrid:
3MZ-FE
Camry Hybrid:
2AZ-FXE
106
Horsepower Calculations
04 09 Prius
Highlander Hybrid
V6 Engine:
Front Drive Motor:
Rear Drive Motor:
HV Battery:
Actual HP
Camry Hybrid
Engine:
Front Drive Motor:
HV Battery:
Actual HP
208 HP
165 HP
67 HP
+ 60 HP
268 HP
147 HP
143 HP
+45 HP
192 HP
Prius Gen 2
1.5L Engine:
Front Drive Motor:
HV Battery:
Actual HP
Prius Gen 3
1.8L Engine:
Front Drive Motor:
HV Battery:
Actual HP
76 HP
68 HP
+ 34 HP
110 HP
98 HP
80 HP
+ 35 HP
134 HP
107
108
2ZR-FXE Engine
04 10 Prius
04-09 MY
10 & later
1NZ-FXE
2ZR-FXE
Displacement (liters)
1.5
1.8
4.3
5.0
3.9
4.4
13.0:1
13.0:1
Horsepower
76 @ 5000
98 @ 5200
85 @ 4200
105 @ 4000
109
134
Maximum Voltage
500
650
AT-PZEV
AT-PZEV
Engine
Compression Ratio
Emission Regulation
109
EGR Valve
Coil
Valve
To Intake
Manifold
EGR Cooler
From EGR Cooler
Silicon Chip
EGR Gas
Cross Section
Engine Coolant
MAP Sensor
(Vacuum Sensor)
110
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111
Shaft
Motor
Electric Water Pump
No accessory belt
New Active Test and
Data List items
New DTCs for pump
112
EGR Cooler
Throttle Body
From Radiator
To Radiator
113
Engine
Coolant
2010 Prius
Combination Meter
Exhaust Gas
Exhaust Pipe Gas
Control Actuator
Valve
Rod
Valve is closed
Valve is open
(Coolant Cold)
114
Gasket
115
Cylinder Block
Drain Cock Plug
Coolant Type
SLLC
Capacity
7.7 qts
Maintenance Interval
(initial)
100,000 miles
Maintenance Interval
(subsequent)
50,000 miles
Radiator Drain
Cock Plug
116
FULL
LOW
117
04 09 Prius
1NZ-FXE
118
to heater core
Water Pump
(for heater)
Coolant Flow
Control Valve
Reverse View
Coolant Heat
Storage Tank
Engine Coolant Temp. Sensor
(for coolant heat storage system)
Water Pump
(for coolant heat
storage system)
119
Bleeding air
from the
system is
critical
Drain Plug
Pump
to/from
Water Valve
120
04 09 Prius
4.5 V (VLV5)
3.5 V (VLV4)
2.5 V
121
Specifications
Fluid
Capacity
9.1 qt (8.6 L)
122
01 03 Prius
1NZ-FXE
123
Intake Pipes
Throttle Control
Motor
Throttle Position
Sensor
Surge Tank
124
TWC
HC Adsorber
TWC with
HC Adsorber
Main Muffler
Bypass Valve Closed
TWC
125
Specifications
Fluid
Capacity
5.2 qt (4.9 L)
126
127
Radiator Cap
Radiator Cap
Cylinder Block
Drain Cock Plug
Radiator Drain Cock Plug
Specifications
Fluid
Capacity
128
Specifications
Fluid
Capacity
6.6 qt.
129
EVAP
01 09 Prius: 1NZ-FXE
130
Fuel Sender
Mounting
Sub Tank
Steel Tank
Interior
131
Reed
Switch
Body
ECU
Meter
ECU
Display
Float
Combination Meter
Fuel Sender
Gauge
132
Inclination Sensors
Combination Meter
Meter
ECU
Combination Meter
Sender
Gauge
Signal
Meter
ECU
Body
ECU
Inclination
Ambient
Temp.
Sensors
InclinationAmbient
Temp
Sensors Sensor
Sensor
Main Tank
01 03 Prius
071 Toyota Hybrid System
Fuel
Sender
Gauge
Main Tank
Fuel
Sender
Gauge
04 09 Prius
133
Fresh Air
Line
01 03 Prius
071 Toyota Hybrid System
04 09 Prius
134
04 09 Prius
Throttle Valve
ORVR REFUELING
ECM
PURGING
Charcoal
Canister
Refuel Check
Valve
Fresh Air
Line
Trap Filter
Vapor Pressure
Sensor
EVAP Line
Filler Pipe
135
EVAP
Highlander Hybrid:
3MZ-FE
071 Toyota Hybrid System
136
THS
ECU
Fuel Vapor
Containment Valve
Canister
Pump Module
137
Refueling Procedure
Highlander Hybrid
138
EVAP
10 & Later Prius:
2ZR-FXE
071 Toyota Hybrid System
139
Fuel System
Bladderless, layered
plastic fuel tank
2010 Prius
Fuel Delivery
Pipe
12-hole Type
Fuel Injector
Quick Connector
140
Purge Line
Fuel Tank
[Pump Module]
Air Inlet
Line
Air Filter
Vent
Valve
* The purge VSV control has changed and the purge flow volume
increased.
Charcoal
Canister
141
OFF
Accelerator
Pedal
IG-ON
READY
ON
IG-ON
(but not
READY ON)
Depress
2 times
Depress
2 times
Depress
2 times
142
143
Brake System
144
Brake Pedal
Stroke Sensor
Steering Angle
Sensor
Yaw Rate and
Acceleration Sensor
Pump Assembly
w/ Accumulator
145
2010-up:
Hydraulic Brake Booster
with Stroke Simulator
20012003:
Hydraulic Boosted
Master Cylinder
2004 to 2009:
Electronic Brake Actuator
with Stroke Simulator
146
04 09 Prius
Highlander
Hybrid
Camry Hybrid
Brake Assist
**
TRAC
HAC
Enhanced VSC
VSC
VDIM
147
Braking
Force
Hydraulic
Braking Force
Regenerative
Braking Force
Time
Changes in Braking Force Apportionment
071 Toyota Hybrid System
148
: Electrical Signal
: Fluid Pressure
Highlander Hybrid
Master Cylinder
Pressure Sensor
EPS
Skid Control ECU
THS-II
Hydraulic Power
Source Portion
Hydraulic Control
Portion
Regenerative
Brake Force
149
Sensor Lever
5
Voltage
SKS2
SKS1
1
0
Brake Pedal
0
60
-15
Sensor Lever Rotational Angle
150
Accumulator/
Actuator
151
Master Cylinder
Brake Booster with Master
Cylinder
Brake Actuator
Stroke
Simulator
Brake Actuator
152
Accumulator
Pump Motor
Fluid Level
Warning
Switch
: Accumulator
Pressure Sensor
: Regulator Pressure Sensor
Stroke
Simulator
Brake Actuator
FR LH
071 Toyota Hybrid System
FR RH
RR LH
RR RH
153
Warning Lights
154
Brake
Warning
Light / Red
ABS Warning
Light
VSC Slip
Indicator
Illuminate
Illuminate
Blink
Illuminate
Illuminate
Illuminate
Warning Light
Conditions
155
Service Details
156
ECB Utilities
157
MAX Line
Fluid Level
Support Line
MIN Line
158
Capacitor Cell
071 Toyota Hybrid System
159
160
Electric Power
Steering
161
162
EPS
ECU
DC motor
Torque sensor
Torque sensor
DC motor
20012003 Prius
EPS
ECU
DC motor
Torque sensor
163
DC Motor
Detection Coil
Correction
Coil
Torsion
Bar
Detection
Ring 3
Detection
Ring 2
Detection
Ring 1
04 09 Prius
01 03 Prius
164
Gateway ECU
Skid Control ECU
Torque Sensor
Meter ECU
Vehicle Speed
signal
Master Warning
Light
Assist torque
demand signal (for
Enhanced VSC*)
EPS Warning
Display Request
Signal to Multi
Display
EPS ECU
Multi Display
Warning display
HV ECU
READY signal
DLC3
DC Motor
165
Power
Steering ECU
Models with
brushless type motor
*
V Bus No.1
DLC3
Steering
Angle
Sensor
Combination
Meter
Skid Control
ECU
Vehicle
Speed Signal
Power
Management
Control ECU
166
Power
Steering ECU
167
04 09 Prius
Column
N.A.
W/Temperature Sensor1
N.A.
Motor Details
DC Motor
Brush type (15-inch wheels)
or Brushless 3-phase Motor*, 2
Brush type
Resolver Type*
N.A.
Hall IC Type
Inductance Type
: Models with brushless type power steering motor only (17inch wheels)
168
ECU replacement
Column assy.
replacement
Left or right effort
differs
Motor Type
Rotation Angle
Torque
Assist Map
Sensor
Sensor Zero
Writing
Initialization
Point
Calibration
Brush
Brushless
169
Steering Angle
Sensor
Spiral Cable
170
EPS Components
Highlander Hybrid
Combination Meter
EPS ECU
THS ECU
171
CAN
Gateway ECU
EPS ECU
Vehicle Speed
signal
Assist torque
demand signal
Meter ECU
P/S Warning
Light
THS ECU
READY signal
Temperature
Sensor
Torque Sensor
Motor
DLC 3
DC-DC Converter
(for EPS)
HV Battery
Voltage: 42 volts
Rotation Angle Sensor
172
173
Highlander EPS
174
175
Air Conditioning
176
177
PTC Heater
PTC
Heaters
Aluminum
Fin
PTC
Element
Brass
Plate
Electrode
PTC
Element
01 03 Prius
Insulation
Film
178
04 09 Prius
01 03 Prius
From
Engine
To
Heater
Highlander Hybrid
179
A/C Inverter
A/C ECU
Electric
Compressor
Evap.
Temp.
Sensor
Heater Core
PTC Heater
180
ES27 compressor
181
Oil Separator
A/C Inverter
Motor
Shaft
Fixed Scroll
Discharge Port
Variable Scroll
Brushless Motor
ES18 compressor
ES27 compressor
182
A/C Inverter
(DC AC)
DC 201.6 V
Oil
Separator
Brushless
Motor
183
184
lls
6 Ce
6C
ell
s
Blower
Motor
185
Tips:
186
A/C System
Press
& Hold
187
Power
HV Battery
188
PlasmaclusterTM Generator
Plasmacluster
Generator
+
+
+
- +
-
Positive and
Negative Ions
2010 Prius
Camry Hybrid
071 Toyota Hybrid System
189
Ejector
2010 Prius
Condenser
Compressor
Expansion
Valve
A A Cross Section
Top Tank
ECS Evaporator
Ejector
Upwind Side
Evaporator
(Downwind Side)
A
Downwind Side
Capillary Tube
Evaporator
(Upwind Side)
Bottom
Tank
190
Ejector
To Evaporator
(Upwind Side)
Nozzle
From Expansion
Valve
Mixing
Portion
Vacuum
Diffuser
Portion
From Evaporator
(Downwind Side)
191
Procedure
Clean
Replace
192
Worksheet 5
193
194
Body Electrical
& Multiplex
Communication
071 Toyota Hybrid System
195
Fuses
Semiconductor
Relays
Front
Power
Distributor
Mode Monitor
Terminal
196
Headlight Leveling
Actuator
Rear Height
Control Sensor (LH)
197
Replace
198
J/B
Junction Block
199
Front Door
Wire Harness
Black (B)
Red (R)
Blue (L)
Green (G)
Yellow (Y)
Brown (BR)
Violet (V)
White-Black (W-B)
Light Green (LG)
Pink (P)
Sky Blue (SB)
200
201
General Maintenance
202
Coolant
10 & later
Prius
Highlander
Camry
87 (1)
87 (1)
87
87 or Higher
87 or Higher
5W-30 (2,3)
5W-30 (2, 3)
0W-20 (6)
5W-30
(06-07)
5W-20(6)
0W-20
(08-09)
0W-20
LLC4)
SLLC
SLLC
SLLC
SLLC
Transaxle Fluid
ATF T-IV
WS ATF
WS ATF
WS ATF
WS ATF
Compressor Oil
ND8
ND11 (5)
ND11 (5)
ND11 (5)
ND11 (5)
Notes:
1. Using a higher octane fuel may prevent normal engine operation.
2. Using a different oil viscosity (such as 10W-30) can cause oil to splash up into the intake manifold.
3. 2001 model specifies API Service SJ. 2002 and newer models specify API Service SL
4. SLLC can be used, however it does not extend the drain interval.
5. ND11 has electrical insulating properties & is the only compressor oil to be used.
6. SAE 5W-20 may be used. 0W-20 is the best choice for good fuel efficiency and good starting in cold weather.
071 Toyota Hybrid System
203
Lubrication System
Element
O-ring
2010 Prius
204
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purpose is to create an extra page for handbook text.
205
2001-2003:
P175/65R14 84S*
2004-2009:
P185/65R15 86S
P195/55R16 86V**
P195/65R15 89S
P215/45R17 87S**
Tire Pressure:
01 03 Prius
206
Auxiliary Battery
TIP:
Take care not to damage temperature sensor during service.
Refer to Repair Manual for systems that must be initialized with a
battery disconnect.
Lead-calcium Alloy
01 03 Prius
04 09 Prius
207
Battery Temp.
Sensor
208
Positive Jumper
Cable
209
Parking Brake is
applied
READY
Vehicle
Stopped
210
Battery Service
Model
01 03 Prius
Auxiliary Battery
S34B20L
S55D23L
Optional battery - See TSB EL014-03
04 09 Prius
Battery Charger
S34B20R
S46B24R
Highlander Hybrid
Lead-Acid: 55B24L
Camry Hybrid
S65D26R
211
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purpose is to create an extra page for handbook text.
212
www.techinfo.toyota.com
213
214