Course 071 Toyota Hybrid System. Welcome. 071 Toyota Hybrid System

Transcription

1 Course Welcome 1

2 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 2

3 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) 3

4 Hybrid System Overview 4

5 Toyota Hybrid Technology Toyota has been researching emission reduction technology since Toyota is the world leader in hybrid technology. 5

6 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 6

7 Toyota Hybrid System (THS) Prius 1NZ-FXE Engine HV Battery Inverter Hybrid Transaxle Motor / Generator 1 Motor / Generator 2 7

8 Hybrid System Overview (THS II) Highlander Hybrid Inverter Assembly HV Battery Engine Rear Drive Unit - Motor Generator Rear (MGR) (4WD-i Only) HV Transaxle - Motor Generator 1 (MG1) - Motor Generator 2 (MG2) 8

9 Hybrid System Engines Highlander Hybrid Prius 1NZ-FXE (1.5L) Prius.1NZ-FXE (1.5L) 10 up Prius 2ZR-FXE (1.8L) Highlander HV 3MZ-FE (3.3L) Camry HV....2AZ-FXE (2.4L) 9

10 Hybrid Drivetrain Components Highlander Hybrid Hybrid Transaxle - MG1 - MG2 Rear Drive Unit - MGR (shown) Rear Drive Unit - Motor Generator Rear (MGR) (4WD-i Only) HV Transaxle - Motor Generator 1 (MG1) - Motor Generator 2 (MG2) 10

11 Hybrid Drivetrain Components Highlander Hybrid Inverter Assembly Inverter Controls current to motor generators Also provides correct voltages to other systems. 11

12 Hybrid Drivetrain Components Highlander Hybrid HV Battery HV Battery Stores electrical energy to drive the system 12

13 Hybrid Vehicle Safety Precaution 2010 Prius All hybrid system high-voltage wire harnesses are orange. The HV battery and other high-voltage components have High Voltage caution labels. Do not carelessly touch these wires and components. 13

14 Hybrid System Control Modes 14

15 READY 15

16 Starting Out 16

17 Engine Starting 17

18 Light Acceleration 18

19 Light Load Cruise 19

20 Full Acceleration 20

21 Deceleration 21

22 Reverse 22

23 Energy Monitor & Fuel Consumption Display Highlander Hybrid 23

24 Push Button Start Insert the key (nonsmart Key equipped, Prius only) Push the POWER switch with the brake pedal depressed ACC IG-ON OFF READY Vehicles enters READY mode 24

25 Worksheet 1 Walkaround 25

26 Worksheet 2 Test Drive 26

27 Warning Lights Prius READY Light Malfunction Indicator Light Low temperature indicator light Master Warning Light 27

28 [END Module 1 Overview] 28

29 Transaxle Operation 29

30 Hybrid Transaxle Prius Silent Chain MG2 MG1 Transaxle Damper Planetary Gear Unit 30

31 Construction of MG1 Stator Coil Rotor Prius Resolver 31

32 Construction of MG Prius Stator Coil Rotor Resolver 32

33 Motor/Generators Total weight is reduced approximately 33% MG2 maximum output is increased to 80 HP Previous Model 2010 Prius 2010 Prius PRIUS MG1 More compact, more light weight design achieved through centralized winding of the coils. MG2 Motor rotational speed was significantly increased, improving power performance P112 P410 33

34 Construction of MGR Highlander Hybrid Resolver Stator Rotor 34

35 Speed Sensor (Resolver) Operation Detects magnetic pole position HV ECU uses the Resolver as a speed sensor and calculates position variations Magnetized Side Stator Coil A Coil B Rotor Coil C Output Side 35

36 Permanent Magnet Motor Generator 36

37 P410 Hybrid Transaxle 2010 Prius MG2 Oil Pump (Mechanical) Compound Gear Unit Power Split Planetary Gear (Right Side) Motor Speed Reduction Planetary Gear (Left Side) Transaxle Damper MG1 Final Drive Gear Final Driven Gear Counter Driven Gear Differential Gear Unit 37

38 Compound Gear Unit - Components 2010 Prius Compound Gear Unit Power Split Planetary Gear Unit Motor Speed Reduction Planetary Gear Unit Counter Drive Gear (Compound Gear) 38

39 Compound Gear Unit - Operation Highlander Hybrid Carrier MG1 MG2 Engine Ring Gear Carrier Counter Driven Gear (To Wheels) 39

40 Transaxle Damper 2010 Prius A coil & torque limiter provide damping Torque limiter Coil spring Transaxle Damper 40

41 P112 Hybrid Transaxle Service Prius 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

42 P410 Hybrid Transaxle Service 2010 Prius Filler Plug for Hybrid Transaxle Fluid Fluid Type Capacity WS 3.5 qts Maintenance Interval (initial) 100,000 miles Maintenance Interval (subsequent) 50,000 miles Drain Plug for Hybrid Transaxle Fluid Drain Plug for Hybrid System Coolant 42

43 P311 Hybrid Transaxle Service Camry Hybrid WS Fluid Fill Plug (10mm hex) 0 to 0.20 in. WS Fluid Drain Plug (10mm hex) Hybrid System Coolant Drain Plug (10mm hex) 43

44 Shift Control P Prius Shift Position Sensor HV ECU Engine ECU (ECM) BEAN Combination Meter 44

45 Shift Assembly P Prius Select Sensor Shift Sensor 45

46 Shift Control Actuator P Prius Cycloid Reduction Mechanism Stator & Coil Shift Control Actuator Rotor Rotation Angle Sensor 46

47 Parking Lock Mechanism P Prius 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

48 Service Tip Prius If you cannot shut the hybrid system OFF, there may be a malfunction in the shift control actuator that is preventing the vehicle from going into park. To solve this problem, stop the vehicle and apply the parking brake. This will bypass the problem, allowing the vehicle to shut down. 48

49 Drive Modes 2010 Prius ECO MODE Moderates the A/C performance to optimize fuel economy EV Mode Driving with only the electric motor PWR MODE Optimizes acceleration performance by increasing the motive force in relation to accelerator pedal operation Normal Motive Force Output Moderates the response to accelerator pedal operation to optimize fuel economy PWR Mode ECO Mode Accelerator Pedal Opening Angle 49

50 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 50

51 Service Tip - P311 Camry Hybrid Transaxle Control Cable Adjustment 1 Shift to N range Lock Piece 4 Slider 2 3 Shift Cable 5 51

52 Instructor Led Demo Transaxle Assembly & Parts Identification 52

53 [END Module 2 Transaxle Operation] 53

54 High Voltage System 54

55 Certified Hybrid Vehicle Technician CAUTION This module does not certify you to work on hybrid vehicle high-voltage systems. The Certified Technician must complete course 071 Toyota Hybrid System to safely begin working on Toyota hybrid vehicles. Until you complete course 071: Never touch, disassemble, remove or replace the high-voltage parts, cables and their connectors. (High-voltage parts and cables are colored orange or have highvoltage warning labels.) Do not try to access the service plug. Failure to comply with these warning can cause severe burns or electric shock that may result in death or serious injury. 55

56 Hybrid Vehicle Safety 56

57 Power Cable Routing Prius Prius HV Battery Inverter Auxiliary Battery A/C Compressor Engine Room Junction Block Auxiliary Battery Inverter Engine Room Junction Block HV Battery Prius Prius Junction Block A/C Compressor HV Battery Inverter 2010-up Prius 57

58 Power Cable Routing Other Models Power Steering Converter A/C Compressor HV Relay Assembly Rear Drive Unit (MGR) Inverter Assembly Battery Smart Unit & HV Relay Assembly HV Battery Highlander Hybrid A/C Compressor Inverter Assembly Camry Hybrid HV Battery DC-DC Converter 58

59 HV Battery 59

60 Nickel-Metal Hydride Battery Prius The Nickel-Metal Hydride (Ni-MH) hybrid vehicle (HV) battery stores electrical energy to drive the system. Nominal battery voltages: Prius 274 VDC 04 & later Prius 202 VDC Highlander Hybrid 288 VDC Camry Hybrid 245 VDC 60

61 HV Battery - Layout Prius Battery Pack Upper Case Battery ECU SMR (System Main Relay) HV Battery Module 61

62 HV Battery - Layout Prius HV Battery Module Front Bus Bar Module SMR 3 Rear Bus Bar Module SMR 2 Battery ECU SMR 1 62

63 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. 63

64 HV Battery State of Charge (SOC) Upper SOC control limit Example of change in SOC Overcharged region Control region SOC Undercharged region Time Lower SOC control limit Target SOC control 64

65 System Main Relays (SMR) 2010 Prius 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 Note: Do NOT remove SMRs on the HV junction block assembly. 65

66 SMR Control SMR2 (+) to Inverter Resistor SMR1 Service Plug HighVoltage Fuse SMR3 (-) to Inverter GND to THS ECU 66

67 Prius HV Battery Cooling Prius Prius 2010-up Prius 67

68 HV Battery Cooling Camry Hybrid Highlander Hybrid 68

69 Inverter 69

70 Inverter Assembly Highlander Hybrid HSD Inverter MG ECU Controls inverter components Boost Converter 288 VDC VDC Inverter AC - DC DC-DC Converter 288 VDC - 12 VDC 70

71 Toyota Hybrid System Charger Front Back 71

72 Safety Steps 72

73 Hybrid Service Safety Precautions See the Repair Manual for vehicle-specific details. 73

74 Preparation 74

75 Service Tip - HV Battery Precautions before working on hybrid system If DTC P0AA6 or P3009 are set, troubleshoot the DTC 1st. DTC Detailed Information Code Display INF Code Information (Trouble Area) P0AA6 Hybrid Battery 526 Insulation abnormality of the entire Voltage high-voltage circuit System 611 Electric Compressor & A/C Inverter Isolation Fault 612 HV Battery, Battery Smart Unit, HV Relay Assembly 613 Hybrid Transmission, Inverter with Converter Assembly 614 DC High-voltage Area 75

76 READY OFF & Securing Smart Key Service Should be performed with READY OFF & key removed from ignition. Secure the smart key at least 10 feet away from the vehicle to provide additional safety. Disconnect the cable from auxiliary battery negative terminal. Approx. 10 ft. radius (not to scale) 76

77 Personal Protective Equipment (PPE) Electrical insulating gloves must be worn when working with Hybrid components. Class 0 gloves offer adequate protection for Toyota Hybrid vehicles. Maximum Use Voltage AC Class Max. Use Voltage AC Class Max. Use Voltage AC Low Voltage High Voltage , , , , ,000 77

78 PPE - Glove Protectors and Liners Protector gloves may be omitted for Class 0 Gloves, under limited use conditions, where small equipment and parts manipulation require unusually good finger dexterity. Clean, dry cloth gloves may be worn inside of insulating gloves for warmth in cold weather or to absorb perspiration in hot weather. 78

79 PPE Certification & Replacement Gloves that have been in-service for six months must either: 1.Be sent out for electrical testing or 2.Disposed of and replaced with new Gloves. 79

80 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 80

81 Insulated Glove Procedures IMPORTANT: DO NOT USE GLOVES IF; THEY ARE WET OR DAMP. IT IS AFTER THE TESTING DUE DATE MARKED ON THE CUFFS (OR MORE THAN 6 MONTHS FROM DATE OF ISSUE). Steps to be taken by the wearer, EVERY TIME, BEFORE putting the Gloves on: Remove all rings and bracelets to avoid any damage to the Gloves. Wash hands with a mild soap & dry hands thoroughly before putting on the Gloves. 81

82 Insulated Glove Care & Storage Note: Exposure to chemicals, solvents, ozone, aging & extreme temperatures can degrade gloves. Follow the instructions for the care, decontamination & maintenance provided by the glove manufacturer or supplier. Good housekeeping can help extend glove life. Also, keep your work area clean from contaminants. Gloves must be stored in their natural shape & protected from physical damage. Gloves should be stored in cool, dark & dry location. Gloves may be kept inside of a bag, box, or container designed for & used exclusively for them. 82

83 Insulated Glove Inspection Before use, check the insulated gloves for cracks, tears and other types of damage by performing the following procedure Place the glove on its side Roll the opening up 2 or 3 times Fold the opening in half to close it Confirm that there are no air leaks 83

84 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 84

85 Caution Notification & Managing Safety Use the provided sign stating: CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION Best Practices include: Confirming that the work area is dry. Confirming that the areas around the hybrid components (HV battery, inverter) are dry. Creating and maintaining a safe zone around hybrid vehicle as appropriate. 85

86 Testing High Voltage Use Underwriters Laboratories approved CAT III (1000V) test equipment. 86

87 Service Plug Removal 87

88 Service Plugs Steps to remove Large type Service Plug 2 Rear Door Scuff Plate LH 1 Protective Cover 2 Steps to remove Small type Service Plug 88

89 Secure Service Plug Keep the removed service plug in a secure location to prevent accidental reconnection while you are working on the high-voltage components. 89

90 Hybrid Vehicle Inverter Precautions Time discharges the capacitors. High-voltage Condensers Dis cha rge Electricity 0V Service plug removal MODEL Discharge WAIT TIME from Service Plug Removal Prius 5 minutes 2010-up Prius 10 minutes Highlander Hybrid 5 minutes Camry Hybrid 10 minutes Time 90

91 Instructor Led Demo Inverter Assembly & Parts Identification 91

92 During HV Repair 92

93 Hybrid Service Safety Precautions Best Practices Prevent conductive objects from completing the circuit between energized conductors. Do not use a universal joint. It can rotate accidentally & complete a circuit. Leaving the battery case open without the cover may expose others to high voltage hazard. Never leave the HV battery unattended with the cover off. 93

94 Insulating Connectors CAUTION: Do not touch any bare cables that may have high-voltage. Cover disconnected high-voltage connectors with insulating vinyl tape Insulated Vinyl Tape 94

95 Chemical Hazards Highlander Hybrid If electrolyte is present at the bottom of the battery case, avoid contact with the fluid. Don t touch! 95

96 HV Battery Recycling Overview All hybrid vehicle HV batteries are recyclable see Warranty Parts Recovery Program for details. 96

97 Proceed with Repair New Nut Old Nut Some inverter nuts and bolts cannot be reused. See RM for inverter installation details. 97

98 HV Battery Post Cleaning On some early models the battery posts may show signs of corrosion. This issue was addressed by Special Service Campaign 40G. 98

99 Instructor Led Demo Prius HV Battery, 10 Prius HV Battery, Camry HV Battery, Highlander HV Battery Assembly & Parts Identification 99

100 After HV Repair 100

101 Hybrid Vehicle Repair Quality Checks Potential Damage After Repair START Installation Hydrogen Vent Hose 101

102 Service Plug Installation After Repair Small Service Plug Installation: Large Service Plug Installation: Click is heard 3 102

103 Precautions for DC-DC Converter 2010 Prius 103

104 Worksheet 3 & 4 HV Systems State of Charge (SOC) 104

105 [END Module 3 High Voltage System] 105

106 Engine 10 & later Prius: 2ZR-FXE Prius: 1NZ-FXE Highlander Hybrid: 3MZ-FE Camry Hybrid: 2AZ-FXE 106

107 Horsepower Calculations 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 2010 & Later Prius 2ZR-FXE 108

109 2ZR-FXE Engine Prius MY 10 & later 1NZ-FXE 2ZR-FXE Displacement (liters) Engine Oil Capacity dry (qts) Engine Oil Capacity w/ filters (qts) :1 13.0:1 Horsepower Torque (ft. lbf) Maximum System Output (hp) Maximum Voltage AT-PZEV AT-PZEV Engine Compression Ratio Emission Regulation Note that if the 5th character in the engine designation is an X, that engine is considered an Atkinson type. 109

110 Exhaust Gas Recirculation System (EGR) 2010 Prius 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

111 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 111

112 Electric Water Pump 2010 Prius Electric Water Pump Stator Rotor Shaft Motor Electric Water Pump No accessory belt New Active Test and Data List items New DTCs for pump 112

113 Cooling System Components 2010 Prius Reservoir Tank Coolant Temperature Sensor EGR Valve Air Release Valve From Heater Core To Heater Core From Exhaust Pipe Gas Control Actuator Electric Water Pump EGR Cooler Throttle Body To Exhaust Pipe Gas Control Actuator From Radiator To Radiator 113

114 Exhaust Heat Recirculation System Coolant Temperature Switch Engine Engine Coolant 2010 Prius Combination Meter Exhaust Gas Exhaust Pipe Gas Control Actuator Valve Rod Valve is closed Valve is open (Coolant Cold) (Coolant Warmed Up) 114

115 Exhaust Heat Recirculation Parts 2010 Prius Exhaust Pipe Gas Control Actuator Case Exhaust Pipe Gas Control Actuator Exhaust Pipe Gas Control Stopper Gasket 115

116 Engine Coolant Change 2010 Prius Air Release Valve Reservoir Tank Cap Cylinder Block Drain Cock Plug Service Tip - follow Repair Manual procedures carefully & use the air release valve to remove all air from the system. Air Release Valve Coolant Type SLLC Capacity 7.7 qts Maintenance Interval (initial) 100,000 miles Maintenance Interval (subsequent) 50,000 miles Radiator Drain Cock Plug 116

117 Service Tips (Engine Coolant Change) 2010 Prius B Line Use the air release valve to remove air from the system. Add SLLC to B line of reservoir tank. Squeeze inlet & outlet hoses & then check coolant level. Run engine in inspection mode to warm it up. After the thermostat is open, allow coolant to circulate for several minutes (approximately 7 minutes). After the engine has cooled, check that coolant level is between FULL & LOW FULL LOW 117

118 04 09 Prius 1NZ-FXE 118

119 Coolant Heat Storage System Prius Engine Coolant Temp. Sensor (for engine control system) 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

120 Coolant Heat Storage Tank Prius Bleeding air from the system is critical Drain Plug Pump to/from Water Valve Outlet Temp. Sensor 120

121 Prius Coolant Heat Storage Operation 2.5 V (VLV3) Prius 4.5 V (VLV5) 3.5 V (VLV4) 2.5 V 121

122 THS-II Engine Coolant Change Prius Specifications Fluid Toyota Super Long Life Coolant (SLLC) Capacity 9.1 qt (8.6 L) Service Tip: Refer to the Repair Manual for details. 122

123 01 03 Prius 1NZ-FXE 123

124 Intake Manifold - 1NZ-FXE Prius Intake Pipes Throttle Control Motor Throttle Position Sensor Surge Tank 124

125 HC Adsorber and Catalyst (HCAC) Prius Actuator TWC HC Adsorber TWC with HC Adsorber Main Muffler Bypass Valve Closed TWC VIEW HC ADSORPTION CATALYST SYSTEM 125

126 THS Engine Coolant Change Bleeder Point Engine Coolant Fill Specifications Fluid Toyota Super Long Life Coolant (SLLC) Capacity 5.2 qt (4.9 L) Service Tip: Refer to the Repair Manual for details 126

127 Highlander Hybrid 3MZ-FE Camry Hybrid 2AZ-FXE 127

128 Highlander Hybrid Engine Coolant Change Highlander Hybrid Highlander Hybrid Radiator Drain Cock Plug (Equipped with Vent Plug) Radiator Drain Cock Plug (Equipped with Vent Plug) Radiator Cap Radiator Cap Cylinder Block Drain Cock Plug Radiator Drain Cock Plug Radiator Drain Cock Plug Cylinder Block Drain Cock Plug Specifications Fluid Toyota Super Long Life Coolant (SLLC) Capacity 13.5 qt. with rear heater 11.2 qt. without rear heater Service Tip: Refer to the Repair Manual for details 128

129 Camry Hybrid Engine Coolant Change Radiator Cap Cylinder Block Drain Cock Plug Radiator Drain Cock Plug Specifications Fluid Toyota Super Long Life Coolant (SLLC) Capacity 6.6 qt. Service Tip: Refer to the Repair Manual for details. 129

130 EVAP Prius: 1NZ-FXE 130

131 Bladder Fuel Tank Prius Resin Bladder Fuel Sender Mounting Sub Tank Steel Tank Interior 131

132 Fuel Sender Gauge Prius Reed Switch Body ECU Meter ECU Display Float Combination Meter Fuel Sender Gauge 132

133 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 Prius Fuel Sender Gauge Main Tank Fuel Sender Gauge Prius 133

134 EVAP Control Components Fresh Air Line VSV (for Canister Closed Valve) Prius Prius 134

135 EVAP Control Components Air Cleaner Prius Throttle Valve ORVR REFUELING ECM PURGING VSV (for Purge Flow Switching Valve) VSV (for EVAP) Charcoal Canister Refuel Check Valve Fresh Air Line Trap Filter Vapor Pressure Sensor EVAP Line Filler Pipe VSV (for Canister Closed Valve) Fuel Tank 135

136 EVAP Highlander Hybrid: 3MZ-FE 136

137 Closed Fuel Tank System Highlander Hybrid THS ECU Fuel Outlet Valve (Closed) Fuel Vapor Containment Valve Canister Pump Module 137

138 Refueling Procedure Highlander Hybrid 138

139 EVAP 10 & Later Prius: 2ZR-FXE 139

140 Fuel System Bladderless, layered plastic fuel tank 2010 Prius Key Off EVAP System Fuel Delivery Pipe 12-hole Type Fuel Injector Quick Connector Fuel Pump Assembly - Fuel Filter - Pressure Regulator - Fuel Sender Gauge 140

141 Fuel System Key OFF EVAP 2010 Prius Fuel Cut-off Valve Vent Line Fuel Filler Check Valve Purge VSV Purge Line Fuel Tank [Pump Module] Air Inlet Line Air Filter Vent Valve Leak Detection Pump ECM Canister Pressure Sensor * The purge VSV control has changed and the purge flow volume increased. Charcoal Canister 141

142 Diagnostic Inspection Modes FWD Inspection Mode within 60 seconds OFF Accelerator Pedal IG-ON READY ON IG-ON (but not READY ON) Depress 2 times Depress 2 times Depress 2 times Change to IG OFF inspection mode is canceled 142

143 [END Module 4 Engine] 143

144 Brake System 144

145 Electronically Controlled Brakes (ECB) Main Body ECU Power Management Control ECU Brake Pedal Stroke Sensor Brake Master Cylinder Reservoir Steering Angle Sensor Yaw Rate and Acceleration Sensor Brake Booster with Master Cylinder Pump Assembly w/ Accumulator Wheel Speed Sensor 145

146 Prius ECB Layout 2010-up: Hydraulic Brake Booster with Stroke Simulator : Hydraulic Boosted Master Cylinder 2004 to 2009: Electronic Brake Actuator with Stroke Simulator 146

147 Brake System Comparison Prius Prius 10 & later Prius Highlander Hybrid Camry Hybrid Regenerative Brake Cooperative Control ABS w/ EBD Hydraulic Brake Booster* Electronically Controlled Braking (ECB) - Brake Assist - ** TRAC HAC Enhanced VSC - - VSC - VDIM * Three channel ECB ** Motor Traction Control function of HV ECU provides a similar function 147

148 Brake Control System - Apportioning of Force 2010 Prius Hydraulic & regenerative force Driver s Demand Braking Force Hydraulic Braking Force Regenerative Braking Force Time Changes in Braking Force Apportionment 148

149 Electronically Controlled Braking System Brake Pedal Stroke Sensor : 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 Hydraulic Brake Force Brake Force 149

150 Brake Pedal Stroke Sensor Prius Brake Pedal Stroke Sensor Stop Light Switch Sensor Lever 5 Voltage SKS2 SKS1 1 0 Brake Pedal 0 60º -15 Sensor Lever Rotational Angle 150

151 Accumulator/ Actuator 151

152 Master Cylinder Brake Booster with Master Cylinder Brake Actuator Stroke Simulator Skid Control ECU 2 Linear Solenoid Valves 4 Switching Solenoid Valves 8 Control Solenoid Valves Pressure sensors for: - Regulator - Wheel Cylinder - Accumulator Brake Actuator 152

153 Brake Hydraulic Circuit 2010 Prius Accumulator Pump Motor Fluid Level Warning Switch Hydraulic Brake Booster : Accumulator Pressure Sensor : Regulator Pressure Sensor Stroke Simulator : Wheel Pressure Sensor Brake Actuator : Linear Solenoid Valve : Switching Solenoid Valve : Pressure Holding Solenoid Valve : Pressure Reduction Solenoid Valve FR LH FR RH RR LH RR RH 153

154 Warning Lights 154

155 Brake Control System - Combination Meter 2010 Prius Warning light illumination Brake Warning Light / Yellow Brake Warning Light / Red ABS Warning Light VSC Slip Indicator TRAC (TRC), VSC or HAC operation Illuminate Malfunction in ABS, EBD or BA - - Illuminate - Malfunction in TRAC (TRC) or VSC - - Blink Malfunction in the apportioning of brake - Illuminate - - Parking brake ON or low brake fluid level - Illuminate - - Illuminate - - Warning Light Conditions System malfunction not affecting brake force Shown above is the 2010 Prius. Other Models are similar. 155

156 Service Details 156

157 ECB Utilities 157

158 Service Tip - Brake Fluid Level 2010 Prius Adjust the fluid level in the reservoir between MIN line & Fluid Level Support Line. MAX Line Fluid Level Support Line MIN Line 158

159 Backup Control Power Source Highlander Hybrid Capacitor Cell 159

160 [END Module 5 Brakes] 160

161 Electric Power Steering 161

162 Electric Power Steering (EPS) Provides power assist even when engine is not running. Improves fuel economy. Consumes energy only when assist is required. 162

163 Electric Power Steering Components EPS ECU DC motor Torque sensor Torque sensor DC motor Camry Hybrid and Highlander Hybrid Prius EPS ECU DC motor Torque sensor 2004 and later Prius 2008 and later Highlander Hybrid 163

164 EPS - Torque Sensor Torque Sensor DC Motor Detection Coil Correction Coil Torsion Bar Detection Ring 3 Detection Ring 2 Detection Ring Prius Prius Torque Sensor Video Torque Sensor Animation 164

165 EPS Steering System Diagram Prius 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

166 Steering System Diagram 2010 Prius Steering Column Assembly Torque Sensor Power Steering ECU Rotation Angle Sensor* Boost Converter* Power Steering Motor 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

167 Brushless & Brush Type EPS 2010 Prius Power Steering ECU Power Steering ECU Steering Column Assembly - Brushless-type Power Steering Motor - Torque Sensor - Rotation Angle Sensor Service Tip: The rotation angle sensor automatically initializes when the vehicle is driven at 22+ mph for 5 seconds with a low yaw rate (straight ahead driving). Steering Column Assembly - Brush-type Power Steering Motor - Torque Sensor 167

168 Steering - Difference from Previous Model Prius Item 2010 & Later Prius Assist Location Type Power Steering ECU Details Prius Column N.A. W/Temperature Sensor1 Voltage Boost Control*, 2 N.A. Motor Details DC Motor Brush type (15-inch wheels) or Brushless 3-phase Motor*, 2 Rotation Angle Sensor Torque Sensor Reduction Mechanism Brush type Resolver Type* N.A. Hall IC Type Inductance Type Worm & Wheel Gear : Models with brushless type power steering motor only (17inch wheels) * 168

169 Service Tip EPS Initialization 2010 Prius Perform initialization & calibration on 2010 Prius EPS as follows: Repair 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 O O Brushless O O O 169

170 Service Tip Spiral Cable 2010 Prius Spiral Cable w/steering Angle Sensor is a complete assembly Combination Switch Assembly Spiral Cable with Steering Angle Sensor Do not remove the steering angle sensor from the spiral cable Do not replace or rotate the spiral cable with the battery connected & engine switch ON Tip: Ensure that the steering wheel is installed & aligned straight when inspecting the steering sensor. Steering Angle Sensor Spiral Cable 170

171 EPS Components Highlander Hybrid Combination Meter EPS ECU P/S Warning Light THS ECU DC - DC Converter (for EPS) Skid Control ECU Steering Gear Unit 171

172 EPS Steering System Highlander Hybrid CAN Gateway ECU BEAN (Instrument Panel Bus) Skid Control 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) Voltage: 288 volts HV Battery Voltage: 42 volts Rotation Angle Sensor 172

173 Highlander Hybrid - Power Steering Precaution Highlander Hybrid The orange harness leading to the EPS DC-DC converter carries 288 VDC. The yellow power steering wire harnesses carry 42 volts. 173

174 Instructor Led Demo Highlander EPS 174

175 [END Module 6 EPS] 175

176 Air Conditioning 176

177 Air Conditioning Compressor Prius Selecting MAX A/C on the Prius will cause the engine to run continuously. 177

178 PTC Heater PTC Heaters Aluminum Fin PTC Element Brass Plate Electrode PTC Element Prius Insulation Film 07 & later Camry Hybrid 178

179 Electric Coolant Pump Provides stable heater performance even with engine stopped To Heater From Engine Prius Bypass Valve Close Prius From Engine To Heater Highlander Hybrid 179

180 Main Air Conditioning Components Prius Solar Sensor A/C Inverter A/C Water Pump A/C ECU Electric Compressor Room Temp. & Humidity Sensor Evap. Temp. Sensor Clean Air Filter Blower Fan Heater Core PTC Heater 180

181 PRECAUTION - Air Conditioning Compressor Camry Hybrid Handle electrical supply (orange cable) to Compressor from the Inverter with care as high voltage may be present. The Air Conditioning Compressor has a dedicated inverter to convert DC Battery Voltage to AC. ES27 compressor 181

182 Electric Compressor Construction 04 & later Prius & Highlander Hybrid Oil Separator A/C Inverter Motor Shaft Fixed Scroll Discharge Port Variable Scroll Brushless Motor ES18 compressor ES27 compressor 182

183 ES14 Compressor Construction 2010 Prius Scroll Type Compressor A/C Inverter (DC AC) DC V Oil Separator Brushless Motor Caution: Use only ND11 type compressor oil. 183

184 Solar Ventilation System & Remote Air Conditioning 2010 Prius Solar Ventilation System can operate indefinitely as long as the operating conditions are met regardless of ambient air temperature. Remote Air Conditioning System will operate for approximately 3 minutes. Solar Ventilation System Remote Air Conditioning System 184

185 Solar Ventilation System Components 2010 Prius Moonroof Solar Module Air Inlet Control Servo Motor Air Outlet Control Servo Motor lls 6 Ce 6C ell s Blower Motor Blower Motor Relay Ventilation Switch Solar Ventilation ECU A/C Amplifier 185

186 Precaution: Solar Ventilation System 2010 Prius CAUTION: Performing repairs with the solar ventilation switch ON may cause the blower motor to operate unexpectedly, resulting in various hazards. Tips: Turn the solar ventilation switch OFF when servicing. Cover the entire solar panel to block sunlight. 186

187 Remote Air Conditioning 2010 Prius Cools the cabin before entering vehicle. Use A/C switch on the remote to activate. A/C System Press & Hold 187

188 PRECAUTION: Remote Air Conditioning 2010 Prius When activated, IG relays are turned ON. Turn the wiper switch & headlight dimmer switch OFF. Store the key securely so that no one cannot operate the remote A/C switch. Power HV Battery 188

189 PlasmaclusterTM Generator Plasmacluster Generator Positive and Negative Ions 2010 Prius Camry Hybrid 189

190 Ejector Cycle System (ECS) Capillary Tube Ejector 2010 Prius Condenser Compressor Expansion Valve A A Cross Section Top Tank ECS Evaporator Ejector Upwind Side A Evaporator (Downwind Side) A Downwind Side Capillary Tube Evaporator (Upwind Side) Bottom Tank 190

191 Ejector Cycle System (ECS) 2010 Prius Ejector To Evaporator (Upwind Side) Nozzle From Expansion Valve Mixing Portion Vacuum Diffuser Portion From Evaporator (Downwind Side) 191

192 Cabin Air Filter Maintenance 2010 Prius Vehicles with Solar Ventilation System require more frequent cabin air filter maintenance as follows: Procedure Without Solar Ventilation With Solar Ventilation Clean Every 15,000 miles Every 10,000 Miles Replace Every 30,000 miles Every 20,000 Miles 192

193 Worksheet 5 EPS, A/C, Brakes, Active Tests 193

194 [END Module 7 Air Conditioning] 194

195 Body Electrical & Multiplex Communication 195

196 Power Distributor Contents Highlander Hybrid Contact Relays Fuses Semiconductor Relays Front Power Distributor Mode Monitor Terminal 196

197 Automatic Headlight Beam Level Prius Service Tip - Initialize system after repair Combination Meter Vehicle Speed Signal Headlight Beam Level Control ECU Master Warning Light Headlight Leveling Actuator Rear Height Control Sensor (LH) 197

198 Automatic Headlight Beam Level Prius Service Tip - Initialization Initialize this system when you reinstall or replace the following items: Reinstall Height Control Sensor Suspension System Replace Height Control Sensor Suspension System Headlight Beam Level Control ECU 198

199 Main Body ECU 2010 Prius Main Body ECU J/B Junction Block 199

200 Painted Wire Harness Painted only near the connector Color (Color Code) 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 [END Module 8 Multiplex] 201

202 General Maintenance 202

203 Hybrid Vehicle Service Specifications Prius Prius Fuel Octane Rating Engine Oil Coolant 10 & later Prius Highlander Camry 87 (1) 87 (1) 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 model specifies API Service SJ 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. 203

204 Lubrication System A replaceable element oil filter is used Filter P/N includes O-ring Pan gasket P/N is Use ILSAC multi-grade engine oil 0W-20 Element O-ring 2010 Prius Note: Do not remove the oil filter bracket clip when removing the oil filter cap assembly. Oil Filter Cap 204

205 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 205

206 Prius - Tire & Wheel : P175/65R14 84S* : P185/65R15 86S P195/55R16 86V** 2010 & later: P195/65R15 89S P215/45R17 87S** Tire Pressure: Front - 35 psi (17 =33psi) Rear - 33 psi (17 =32psi) * Extra load carrying capacity (XL) must be used ** option Prius 206

207 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 Prius Prius 207

208 Service - Auxiliary Battery 2010 Prius Do NOT perform a quick charge. Replace with dedicated battery only (S46B24R) Location of Auxiliary Battery Auxiliary Battery (Sealed-type) Hydrogen Drain Port Battery Temp. Sensor 208

209 Auxiliary Battery Jump Start Terminal Prius Main Junction Block Jumper Cable Tab Negative Jumper Cable Positive Jumper Cable 10 & later Prius 209

210 Emergency Stop & Start Function 2010 Prius If vehicle does not appear to READY OFF, change Power source mode If parking lock actuator malfunctions, it cannot shift position into P Parking Brake is applied READY Power Source Mode OFF is not possible Vehicle Stopped Power Source Mode OFF is possible 210

211 Battery Service Model Prius Auxiliary Battery S34B20L S55D23L Optional battery - See TSB EL Prius Battery Charger S34B20R Special Smart charger: YA122-01* Only perform a slow charge (3.5 A or less). S46D24R (on vehicles w/smart key and/or Navigation) 10 & later Prius S46B24R Only perform a slow charge (4.2 A or less). Highlander Hybrid Lead-Acid: 55B24L Only perform a slow charge (5.0 A or less) (Associated #ASE 6003 or Christie #CAPPDQ) Camry Hybrid S65D26R Only perform a slow charge (5.0 A or less). 211

212 This slide is hidden. It does not appear in the slide show. Its purpose is to create an extra page for handbook text. 212

213 Emergency Response Guide 213

214 [END Module 9 General Service] 214