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Toyota Prius 2010 Repair Manual

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COMPONENTS
ILLUSTRATION
ILLUSTRATION
2010 Toyota Prius
Repair Manual

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Summary of Contents for Toyota Prius 2010

  • Page 1 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 2 2010 Toyota Prius Repair Manual...
  • Page 3 6. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Disconnect each connector and remove the screw. (b) Disengage the guide as shown in the illustration. (c) Disengage the guide and remove the air conditioning amplifier assembly as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 4 2010 Toyota Prius Repair Manual...
  • Page 5 (b) Engage the guide and install the air conditioning amplifier assembly as shown in the illustration. (c) Install the screw and connect each connector. 2. INSTALL FRONT NO. 1 CONSOLE BOX INSERT 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 6 When disconnecting the cable, some systems need to be initialized after the cable is reconnected 4. INSTALL REAR NO. 3 FLOOR BOARD 5. INSTALL REAR DECK FLOOR BOX 6. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) 2010 Toyota Prius Repair Manual...
  • Page 7 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 8 (b) Disconnect the connector. NOTICE: Since the connectors for the air conditioning control assembly and the integration control and panel sub- assembly are the same shape, mark them so that they will not be reconnected incorrectly. 2010 Toyota Prius Repair Manual...
  • Page 9 (b) Engage the 4 claws to install the air conditioning control assembly. 2. INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH 3. INSTALL LOWER CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 4. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 10 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 11 2010 Toyota Prius Repair Manual...
  • Page 12 When disconnecting the cable, some systems need to be initialized after the cable is reconnected 6. REMOVE AIR CONDITIONING PRESSURE SENSOR (a) Disconnect the connector. (b) Remove the air conditioning pressure sensor. NOTICE: Do not deform the piping. 2010 Toyota Prius Repair Manual...
  • Page 13 3. INSTALL REAR NO. 3 FLOOR BOARD 4. INSTALL REAR DECK FLOOR BOX 5. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) 6. CHARGE WITH REFRIGERANT 7. WARM UP COMPRESSOR 8. INSPECT FOR REFRIGERANT LEAK 2010 Toyota Prius Repair Manual...
  • Page 14 6. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cold water. CAUTION: 2010 Toyota Prius Repair Manual...
  • Page 15 A/C system is turned on or off. 13. PRECAUTIONS TO BE OBSERVED WHILE SERVICING CAUTION: Always use electric insulating gloves and remove the service plug grip before beginning inspection, as inspection of the A/C system requires disconnecting high voltage connectors. 2010 Toyota Prius Repair Manual...
  • Page 16 Make sure to store the key (electrical transmitter) in a box with the switch side facing up, and place the box where it can be monitored so that no one cannot operate the remote A/C switch. (b) When performing repairs on vehicles with the solar ventilation system, turn the solar ventilation switch off. CAUTION: 2010 Toyota Prius Repair Manual...
  • Page 17 Depending on the environment around the vehicle, performing repairs with the solar ventilation switch on may cause the blower motor to operate unexpectedly, resulting in various hazards. This can lead to damage to parts or a serious injury. 2010 Toyota Prius Repair Manual...
  • Page 18 PARTS LOCATION ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 19 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 20 2010 Toyota Prius Repair Manual...
  • Page 21 SYSTEM DIAGRAM 1. Air Conditioning System 2010 Toyota Prius Repair Manual...
  • Page 22 A/C inverter main power supply voltage signal A/C inverter output signal A/C inverter internal power source malfunction Power management A/C amplifier control ECU STB wire short State of STB A/C inverter temperature information Compressor start flag 2010 Toyota Prius Repair Manual...
  • Page 23 MODE switch signal REC/FRS switch signal A/C control assembly A/C amplifier Micro dust and pollen filter mode switch signal Blower switch signal (FAN+, FAN-, OFF) Set temperature switch signal (UP, DOWN) 2. Remote Air Conditioning System 2010 Toyota Prius Repair Manual...
  • Page 24 Communication Table Communication Sender Receiver Signal Line Remote air conditioning system Key (Electrical activation request signal Certification ECU Radio waves Transmitter) Remote air conditioning system stop 2010 Toyota Prius Repair Manual...
  • Page 25 Section) A/C Amplifier Remote air conditioning system activation prohibition signal Remote air conditioning system OFF A/C Amplifier Main Body ECU request signal HINT: For details of the remote air conditioning system, refer to System Description 2010 Toyota Prius Repair Manual...
  • Page 26 A/C amplifier turns on the PTC heater assembly if the conditions listed below are met: PTC Heater Control*1 Engine coolant temperature is below specified temperature. Outside temperature is below specified temperature Tentative air mix damper opening angle is above the specified value (MAX 2010 Toyota Prius Repair Manual...
  • Page 27 Accordingly, the A/C amplifier controls the servo motors and blower motor in accordance with the control volumes that have been calculated by the neural network control. 2010 Toyota Prius Repair Manual...
  • Page 28 3. MODE POSITION AND DAMPER OPERATION (a) Mode Position and Damper Operation 2010 Toyota Prius Repair Manual...
  • Page 29 FOOT Air blows out of the front and rear footwell register J, H ducts, and side registers. In addition, air blows out slightly from the center defroster and side defrosters. 2010 Toyota Prius Repair Manual...
  • Page 30 FACE Air blows out of the front center register and side I, E register ducts. 4. AIR OUTLETS AND AIRFLOW VOLUME (a) Air Outlets and Airflow Volume FACE FOOT Indication Mode SIDE 2010 Toyota Prius Repair Manual...
  • Page 31 Hood is closed. Brake Pedal Not operated (not depressed) Security Not in alarm sounding state Shift Selection Park (P) is selected. HV battery state of charge is sufficient. HV Battery (Reference value: level 3 or higher) 2010 Toyota Prius Repair Manual...
  • Page 32 However, a rapid decrease in the refrigerant pressure forms swirls, causing energy loss. In this ejector cycle, the energy loss caused by the cooler expansion valve is utilized by the operation of the ejector that injects and expands a high-pressure refrigerant, thus improving energy consumption efficiency. 2010 Toyota Prius Repair Manual...
  • Page 33 (d) This control usually operates for approximately 3 minutes. However, when the outside temperature is low (5°C (41°F) maximum), it will operate for approximately 1 minute. (e) After this control stops operating, the A/C amplifier controls the air conditioning system using AUTO mode. 2010 Toyota Prius Repair Manual...
  • Page 34 The Plasmacluster (ion generator) uses a high voltage, which is hazardous. Therefore, if the Plasmacluster (ion generator) requires repairs, be sure to have them done at a TOYOTA dealer. Do not apply any type of spray (such as a cleaning solvent or hair spray) or stick any foreign matter into the Plasmacluster ion outlet, as this could cause improper operation or a malfunction.
  • Page 35 ECO MODE switch is in Control the on state, thus improving fuel economy. Compressor Speed Restricts the maximum speed during cooling and reduces the power consumption. Restriction Control 2010 Toyota Prius Repair Manual...
  • Page 36 (2) The PTC heater assembly consists of a PTC element, aluminum fin, and brass plate. When current is applied to the PTC element, it generates heat to warm the air that passes through the unit. 2010 Toyota Prius Repair Manual...
  • Page 37 The blower motor has a built-in blower controller, and is controlled using duty control performed by the A/C amplifier. 13. BUS CONNECTOR (AIR CONDITIONING HARNESS) (a) A Bus connector is used in the wire harness connection that connects the servo motor from the A/C amplifier. 2010 Toyota Prius Repair Manual...
  • Page 38 (b) Each Bus connector has a built-in communication/driver IC which communicates with each servo motor connector, actuates the servo motor, and has a position detection function. This enables bus communication for the servo motor wire harness, for a more lightweight construction and a reduced number of wires. 2010 Toyota Prius Repair Manual...
  • Page 39 ON-OFF signals to the A/C amplifier based on the difference of the pulse phases. The BUS connector can detect the damper position and movement direction with these signals. 2010 Toyota Prius Repair Manual...
  • Page 40 The solar sensor (automatic light control sensor) detects the changes in the amount of sunlight and outputs it to the A/C amplifier in the form of voltage changes. 19. A/C PRESSURE SENSOR The A/C pressure sensor detects the refrigerant pressure and outputs it to the A/C amplifier in the form of voltage changes. 2010 Toyota Prius Repair Manual...
  • Page 41 B GO TO LIN COMMUNICATION SYSTEM CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Use the Techstream to check if the CAN communication system is functioning normally. Result: Result Proceed to CAN DTC is not output 2010 Toyota Prius Repair Manual...
  • Page 42 Result: Result Proceed to Fault is not listed in Problem Symptoms Table Fault is listed in Problem Symptoms Table B Go to step 9 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Panel diagnosis (indicator check, sensor check) 2010 Toyota Prius Repair Manual...
  • Page 43 (b) Data List / Active Test (c) Terminals of ECU (d) Operation Check (w/ Remote Air Conditioning System)) (e) On-vehicle Inspection (f) Inspection NEXT ADJUST, REPAIR OR REPLACE NEXT END 2010 Toyota Prius Repair Manual...
  • Page 44 Use 2 keys (electrical transmitters). Confirm that the wireless door lock functions operate normally. (1) Prepare 2 registered keys (electrical transmitters), and label one of them key (electrical transmitter) A, and the other key (electrical transmitter) B. 2010 Toyota Prius Repair Manual...
  • Page 45 If the remote air conditioning system is not operated for one of the keys (electrical transmitter) A or B, the key (electrical transmitter) needs to be replaced because a malfunction of the remote A/C switch on the key (electrical transmitter) is suspected. 2010 Toyota Prius Repair Manual...
  • Page 46 Function to set the stop operation method for the 1 tim ON, 2 tim ON, Stop Pre A/C*1 2 tim ON remote air conditioning system using the key Long1 or Long2 (electrical transmitter). *1: w/ Remote Air Conditioning System 2010 Toyota Prius Repair Manual...
  • Page 47 Refrigerant volume Refrigerant pressure Air conditioning pressure sensor circuit Air mix damper control servo motor circuit Temperature control: No cool air comes out Evaporator temperature sensor circuit Room temperature sensor circuit Ambient temperature sensor circuit 2010 Toyota Prius Repair Manual...
  • Page 48 Room temperature sensor circuit Temperature control: Output air is warmer or cooler than the set Ambient temperature temperature or response is slow sensor circuit Evaporator temperature sensor circuit Air mix damper control servo motor circuit 2010 Toyota Prius Repair Manual...
  • Page 49 A/C amplifier Air outlet damper control servo motor circuit No air flow mode control Air conditioning control panel circuit A/C amplifier PTC heater circuit Heater performance is low (engine is stopped)*2 A/C amplifier 2010 Toyota Prius Repair Manual...
  • Page 50 Data List (FL Door Courtesy, FR Door though a wireless door lock is performed when the remote Courtesy, RL Door Courtesy SW, RR A/C switch on the key (electrical transmitter) is pressed. (air Door Courtesy SW, Back Door Courtesy 2010 Toyota Prius Repair Manual...
  • Page 51 A/C switch on the key (electrical transmitter). A/C amplifier Power management control ECU Certification ECU *1: w/ Solar Ventilation System *2: w/ PTC Heater Assembly *3: w/ Plasmacluster (Ion Generator) *4: w/ Remote Air Conditioning System 2010 Toyota Prius Repair Manual...
  • Page 52 , 455 psi) and more than 196 kPa (2.0 kgf/cm , 28 psi)) L17-10 (S5-3) Power switch on (IG) Power supply for A/C 4.75 to 5.25 - L17-13 (SG- B - G pressure sensor A/C switch on 2010 Toyota Prius Repair Manual...
  • Page 53 Blower switch on Below 1 V signal 14 (GND)*3 (plasmacluster operating) L17-18 PTC heater operation Engine is running (1250 rpm or higher) (PTC1) - L17- W - W-B 11 to 14 V signal 14 (GND)*1 2010 Toyota Prius Repair Manual...
  • Page 54 1.2 to 1.6 V L17-34 (SG-1) sensor signal Cabin temperature: 40°C (104°F) Power switch on (IG) L17-33 (TS) - BR - W- Solar sensor signal 0.8 to 4.3 V L17-14 (GND) Solar sensor subjected to electric light 2010 Toyota Prius Repair Manual...
  • Page 55 Below 1 V z11-4 (B BUS) Power supply for BUS - z11-2 (BUS Power switch on (IG) 11 to 14 V z11-5 (SGA) - Ground for evaporator Always Below 1 V Body ground temperature sensor 2010 Toyota Prius Repair Manual...
  • Page 56 (GND) Tool Setting 1 V/DIV., 100 ms/DIV. Power switch on (IG) Vehicle SBI terminal: 7 V or higher Condition Solar ventilation system: off HINT: The waveform varies with the communication content. 2. A/C CONTROL ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 57 Light control switch G - W-B Light control switch signal 11 to 14 V (ILL-) tail or head L20-8 (GND) - Body W-B - Body Ground for front A/C control Always Below 1 V ground ground assembly 2010 Toyota Prius Repair Manual...
  • Page 58 2. CHECK DLC3 (a) Check the DLC3 3. LIST OF OPERATION METHODS (a) By operating each of the air conditioning control switches as shown in the diagram below, it is possible to enter diagnostic check mode. 2010 Toyota Prius Repair Manual...
  • Page 59 4. INDICATOR CHECK (a) Turn the power switch off. (b) Turn the power switch on (ACC) and wait for at least 5 seconds. (c) Turn the power switch on (IG) while pressing the A/C control 2010 Toyota Prius Repair Manual...
  • Page 60 (c) Read the DTC displayed on the A/C control assembly. NOTICE: In sensor check mode, which is automatically entered after indicator check mode, troubleshooting may be partially performed. Be sure to perform the sensor check again. 2010 Toyota Prius Repair Manual...
  • Page 61 Press the "OFF" switch to finish panel diagnosis. Text in Illustration A/C Control Assembly (e) Clear the DTC (1) During the sensor check, press the "FRONT DEF" switch and "MODE" switch simultaneously. Text in Illustration A/C Control Assembly 2010 Toyota Prius Repair Manual...
  • Page 62 (b) Turn the power switch on (IG). (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Air Conditioner / Trouble Codes. (e) Clear the DTCs by pressing the YES button on the Techstream display. 2010 Toyota Prius Repair Manual...
  • Page 63 Actual ambient temperature displayed Sensor Max.: 65.95°C (150.71°F) Adjusted ambient temperature / Adjusted Ambient Min.: -30.8°C (-23.44°F) Temp Max.: 50.8°C (123.44°F) Evaporator temperature sensor / Evaporator Fin Min.: -29.7°C (-21.46°F) Actual evaporator temperature displayed Thermistor Max.: 59.55°C (139.19°F) 2010 Toyota Prius Repair Manual...
  • Page 64 Air mix servo motor actual pulse MAX. COLD: 6 (pulse) Air Mix Servo Actual Pulse (D) Min.: 0 MAX. HOT: 93 (pulse) Max.: 255 FACE: 47 (pulse) Air Outlet Servo Air outlet servo motor target Pulse (D) 2010 Toyota Prius Repair Manual...
  • Page 65 Heater active level / Electric Heater Min.: 0 Actual electric heater active level displayed - Active Level*1 Max.: 3 ECO MODE switch / OFF: ECO MODE switch off ECO Switch OFF or ON ON: ECO MODE switch on 2010 Toyota Prius Repair Manual...
  • Page 66 Data List information can be displayed while performing Active Tests. (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Air Conditioner / Active Test. 2010 Toyota Prius Repair Manual...
  • Page 67 Min.: 0, Max.: 255 Air Inlet Damper Targ Pulse Air inlet damper target pulse Min.: 0, Max.: 255 Air Purifier Mode*2 Plasmacluster (ion generator) Stop, Ion, Clean *1: w/ PTC Heater Assembly *2: w/ Plasmacluster (Ion Generator) 2010 Toyota Prius Repair Manual...
  • Page 68 7. Cooling fan system (condenser cannot be cooled down) 8. A/C system (leaks, blocked) Air Mix Damper Control Memorized 1. Air mix control servo motor B1441/41 Servo Motor Circuit (Passenger Side) (30 sec. or 2010 Toyota Prius Repair Manual...
  • Page 69 4. Hybrid control system 5. CAN communication system 1. Compressor with motor assembly B1474/74 A/C Inverter Malfunction Memorized 2. CAN communication system 1. Cooling fan system A/C Inverter Cooling / B1475/75 Memorized Heating System Malfunction 2. Refrigerant volume 2010 Toyota Prius Repair Manual...
  • Page 70 (ion generator) and A/C amplifier Memorized B14A1*3 Air Purifier Open Circuit 3. Harness or connector between (4 sec. or plasmacluster (ion generator) and battery more) 4. Harness or connector between plasmacluster (ion generator) and body ground 2010 Toyota Prius Repair Manual...
  • Page 71 2. Power management control ECU Hybrid Control System DTC Code Detection Item Trouble Area Memory page 1. Compressor oil 2. Refrigerant pipe line P0AA6- Hybrid Battery Voltage System Isolation Fault 3. Compressor with motor assembly 4. CAN communication system 2010 Toyota Prius Repair Manual...
  • Page 72 *2: If the ambient temperature is approximately -52.9°C (-63.22°F) or lower, DTC B1412/12 may be output even though the system is normal. *3: w/ Plasmacluster (Ion Generator) *4: The A/C amplifier stores the DTC of the respective malfunction if it has occurred for the period of time indicated in the brackets. 2010 Toyota Prius Repair Manual...
  • Page 73 Open or short in room temperature B1411/11 and A/C amplifier sensor circuit A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE READ VALUE USING TECHSTREAM (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). 2010 Toyota Prius Repair Manual...
  • Page 74 OK (When troubleshooting according to the DTC) REPLACE A/C AMPLIFIER PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE INSPECT ROOM TEMPERATURE SENSOR (a) Remove the room temperature sensor. (b) Disconnect the room temperature sensor connector. 2010 Toyota Prius Repair Manual...
  • Page 75 L44-1 - L44-2 45°C (113°F) 0.65 to 0.85 kΩ L44-1 - L44-2 50°C (122°F) 0.50 to 0.70 kΩ L44-1 - L44-2 55°C (131°F) 0.44 to 0.60 kΩ L44-1 - L44-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 76 Always Below 1 Ω L17-34 (SG-1) - L44-2 Always Below 1 Ω L17-29 (TR) - Body ground Always 10 kΩ or higher L17-34 (SG-1) - Body ground Always 10 kΩ or higher Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 77 Front view of wire harness connector (to A/C Amplifier) Front view of wire harness connector (to Room Temperature Sensor) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 78 Harness or connector between ambient temperature Open or short in ambient temperature B1412/12 sensor and A/C amplifier sensor circuit A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE READ VALUE USING TECHSTREAM (a) Connect the Techstream to the DLC3. 2010 Toyota Prius Repair Manual...
  • Page 79 OK (When troubleshooting according to the DTC) REPLACE A/C AMPLIFIER PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE INSPECT AMBIENT TEMPERATURE SENSOR (a) Remove the ambient temperature sensor. (b) Disconnect the ambient temperature sensor connector. 2010 Toyota Prius Repair Manual...
  • Page 80 A4-1 - A4-2 45°C (113°F) 0.65 to 0.85 kΩ A4-1 - A4-2 50°C (122°F) 0.50 to 0.70 kΩ A4-1 - A4-2 55°C (131°F) 0.44 to 0.60 kΩ A4-1 - A4-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 81 Always Below 1 Ω L17-13 (SG-2) - A4-2 Always Below 1 Ω L17-5 (TAM) - Body ground Always 10 kΩ or higher L17-13 (SG-2) - Body ground Always 10 kΩ or higher Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 82 Front view of wire harness connector (to A/C Amplifier) Front view of wire harness connector (to Ambient Temperature Sensor) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 83 Air conditioning harness B1413/13 Open or short in evaporator temperature sensor circuit A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE READ VALUE USING TECHSTREAM (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). 2010 Toyota Prius Repair Manual...
  • Page 84 OK (When troubleshooting according to the DTC) REPLACE A/C AMPLIFIER PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE INSPECT EVAPORATOR TEMPERATURE SENSOR (a) Remove the evaporator temperature sensor. (b) Disconnect the evaporator temperature sensor connector. 2010 Toyota Prius Repair Manual...
  • Page 85 30°C (86°F) 1.11 to 1.32 kΩ NOTICE: Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature. 2010 Toyota Prius Repair Manual...
  • Page 86 Below 1 Ω z11-6 (TEA) - Body ground Always 10 kΩ or higher z11-5 (SGA) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to A/C Amplifier) 2010 Toyota Prius Repair Manual...
  • Page 87 Front view of wire harness connector (to Evaporator Temperature Sensor) REPLACE AIR CONDITIONING HARNESS REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 88 (3.14 MPa (32.0 kgf/cm , 455 psi) or more). capacity due to dirt) Cooler dryer (moisture in the refrigerant cycle cannot be absorbed) Cooling fan system (condenser cannot be cooled down) A/C system (leaks, blocked) WIRING DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 89 (a) Disconnect the A/C pressure sensor connector. (b) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Switch Condition Specified Condition A31-3 (+) - Body ground Power switch on (IG) 4.75 to 5.25 V 2010 Toyota Prius Repair Manual...
  • Page 90 (to A/C Pressure Sensor) CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C PRESSURE SENSOR) INSPECT A/C PRESSURE SENSOR (SENSOR SIGNAL CIRCUIT) (a) Reconnect the A/C pressure sensor connector. (b) Remove the A/C amplifier with the connectors still connected. 2010 Toyota Prius Repair Manual...
  • Page 91 CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C PRESSURE SENSOR) INSPECT A/C PRESSURE SENSOR (SENSOR SIGNAL CIRCUIT) (a) Measure the voltage when the following conditions are satisfied. Item Condition Vehicle Doors Fully open Temperature Setting MAX COLD Blower Speed A/C Switch 2010 Toyota Prius Repair Manual...
  • Page 92 OK (When troubleshooting according to the DTC) OK (When troubleshooting according to Problem Symptoms Table) Text in Illustration Component with harness connected (A/C Amplifier) INSPECT COOLING FAN SYSTEM PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 93 Front view of wire harness connector (to A/C Pressure Sensor) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE A/C AMPLIFIER CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C PRESSURE SENSOR) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 94 Front view of wire harness connector (to A/C Pressure Sensor) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE A/C AMPLIFIER CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C PRESSURE SENSOR) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 95 (a) Install the manifold gauge set. (b) Recover the refrigerant from the A/C system using a refrigerant recovery unit. (c) Evacuate the A/C system and check that vacuum can be maintained. Vacuum can be maintained in the A/C system. 2010 Toyota Prius Repair Manual...
  • Page 96 When the outside air temperature is low (below -1.5°C (29.3°F)), the compressor stops due to signals from the ambient temperature sensor and the evaporator temperature sensor to prevent the evaporator from freezing. In this case, perform the inspection in a warm indoor environment. Result: Result Proceed to DTC B1423/23 is output 2010 Toyota Prius Repair Manual...
  • Page 97 L17-9 (PRE) - Normal pressure (less than 3.187 1.0 to 4.912 V L17-13 (SG-2) MPa [462 psi] and more than 0.39 MPa [57 psi]) Text in Illustration Component with harness connected (A/C Amplifier) REPLACE A/C PRESSURE SENSOR 2010 Toyota Prius Repair Manual...
  • Page 98 Therefore, recover the refrigerant and properly evacuate the system. Add an appropriate amount of refrigerant, and check for DTCs. NEXT RECHECK FOR DTC (a) Recheck for the DTC when the following conditions are satisfied. 2010 Toyota Prius Repair Manual...
  • Page 99 (a) Replace the expansion valve with a new or a known good one HINT: Replace the expansion valve with a new or a known good one because the expansion valve is either stuck or clogged. 2010 Toyota Prius Repair Manual...
  • Page 100 In this case, clean or replace the condenser or pipes. Result: Result Proceed to DTC B1423/23 is not output DTC B1423/23 is output REPLACE CONDENSER 2010 Toyota Prius Repair Manual...
  • Page 101 In this case, perform the inspection in a warm indoor environment. Result: Result Proceed to DTC B1423/23 is not output DTC B1423/23 is output REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 102 2010 Toyota Prius Repair Manual...
  • Page 103 Trouble Area Air mix control servo motor Air mix damper position sensor value does not change even if A/C Air conditioning B1441/41 amplifier operates air mix control servo motor harness A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE 2010 Toyota Prius Repair Manual...

  • Page 104: Table Of Contents

    The display is as specified in the Normal Condition column. Result: Result Proceed to OK (When troubleshooting according to Problem Symptoms Table) OK (When troubleshooting according to the DTC) REPLACE A/C AMPLIFIER PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE 2010 Toyota Prius Repair Manual...
  • Page 105 (b) Check for the DTC. Result: Result Proceed to DTC B1441/41 is output DTC B1441/41 is not output END (AIR MIX CONTROL SERVO MOTOR WAS DEFECTIVE) INSPECT AIR CONDITIONING HARNESS 2010 Toyota Prius Repair Manual...
  • Page 106 (b) Check for the DTC. Result: Result Proceed to DTC B1441/41 is output DTC B1441/41 is not output END (AIR CONDITIONING HARNESS WAS DEFECTIVE) REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 107 Trouble Area Air inlet control servo motor Air inlet damper position sensor value does not change even if A/C Air conditioning B1442/42 amplifier operates air inlet control servo motor harness A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE 2010 Toyota Prius Repair Manual...

  • Page 108: Tester Display Measurement Item/Range

    Proceed to OK (When troubleshooting according to Problem Symptoms Table) OK (When troubleshooting according to the DTC) REPLACE A/C AMPLIFIER PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE PERFORM ACTIVE TEST USING TECHSTREAM 2010 Toyota Prius Repair Manual...
  • Page 109 (b) Check for the DTC. Result: Result Proceed to DTC B1442/42 is output DTC B1442/42 is not output END (AIR INLET CONTROL SERVO MOTOR WAS DEFECTIVE) INSPECT AIR CONDITIONING HARNESS (a) Replace the air conditioning harness 2010 Toyota Prius Repair Manual...
  • Page 110 (b) Check for the DTC. Result: Result Proceed to DTC B1442/42 is output DTC B1442/42 is not output END (AIR CONDITIONING HARNESS WAS DEFECTIVE) REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 111 Trouble Area Air outlet control servo motor Air outlet damper position sensor value does not change even if A/C Air conditioning B1443/43 amplifier operates air outlet control servo motor harness A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE 2010 Toyota Prius Repair Manual...

  • Page 112: (D) Max

    Air outlet servo motor actual pulse / Min.: 0, FOOT: 17 (pulse) Pulse (D) Max.: 255 FOOT/DEF: 9 (pulse) DEF: 5 (pulse) The display is as specified in the Normal Condition column. Result: Result Proceed to 2010 Toyota Prius Repair Manual...
  • Page 113 Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a new or a known good one and check that the condition returns to normal. (b) Check for the DTC. Result: 2010 Toyota Prius Repair Manual...
  • Page 114 (b) Check for the DTC. Result: Result Proceed to DTC B1443/43 is output DTC B1443/43 is not output END (AIR CONDITIONING HARNESS WAS DEFECTIVE) REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 115 Open or short in A/C inverter high compressor with motor assembly and inverter with voltage power resource system. converter assembly) B1471/71 The boost pressure system is Compressor with motor assembly broken or malfunctioning. Hybrid control system CAN communication system WIRING DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 116 Be sure to carry the removed service plug grip because other workers may install it by mistake. Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 117 Be sure to wear insulated gloves. (a) Turn the power switch off. (b) Remove the service plug grip. CAUTION: Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 118 Tester Item Condition Specified Condition (Tester Connection) ELECTRIC VEHICLE fuse Always Below 1 Ω (A - B) Text in Illustration Inverter with Converter Assembly Electric Vehicle Fuse REPLACE ELECTRIC VEHICLE FUSE INSPECT NO. 2 ENGINE WIRE 2010 Toyota Prius Repair Manual...
  • Page 119 Text in Illustration Front view of wire harness connector (to Compressor with Motor Assembly) Front view of wire harness connector (to Inverter with Converter Assembly) REPLACE NO. 2 ENGINE WIRE REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 120 (a) Using the Techstream to check if the CAN communication system is functioning normally. Result: Result Proceed to CAN DTC is not output CAN DTC is output B GO TO CAN COMMUNICATION SYSTEM A REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 121 Harness or connector between power management control ECU and compressor with motor assembly Compressor with motor assembly Open or short in A/C inverter B1473/73 Power management control ECU start-up signal system. Hybrid control system CAN communication system WIRING DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 122 Be sure to carry the removed service plug grip because other workers may install it by mistake. Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 123 DTCs other than P3108 are output for hybrid control system GO TO HYBRID CONTROL SYSTEM GO TO DTC B1498/98 CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - COMPRESSOR WITH MOTOR) CAUTION: Do not disconnect the connector on the high-voltage side. 2010 Toyota Prius Repair Manual...
  • Page 124 10 kΩ or higher Text in Illustration Front view of wire harness connector (to Power Management Control ECU) Front view of wire harness connector (to Compressor with Motor Assembly) REPAIR OR REPLACE HARNESS OR CONNECTOR 2010 Toyota Prius Repair Manual...
  • Page 125 A21-20 (STB) - Body Power switch off Below 1 V ground Text in Illustration Front view of wire harness connector (to Power Management Control ECU) REPLACE COMPRESSOR WITH MOTOR ASSEMBLY REPLACE POWER MANAGEMENT CONTROL ECU 2010 Toyota Prius Repair Manual...
  • Page 126 (a) Using the Techstream to check if the CAN communication system is functioning normally. Result: Result Proceed to CAN DTC is not output CAN DTC is output B GO TO CAN COMMUNICATION SYSTEM A REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 127 CHECK CAN COMMUNICATION SYSTEM (a) Using the Techstream to check if the CAN communication system is functioning normally. Result: Result Proceed to CAN DTC is not output CAN DTC is output GO TO CAN COMMUNICATION SYSTEM 2010 Toyota Prius Repair Manual...

  • Page 128: Max Cold

    (b) Read the manifold gauge pressure when the following conditions are established. (1) Prepare the vehicle according to the chart below. Item Condition Vehicle Doors All fully open Temperature Setting MAX COLD Blower Speed A/C switch RECIRCULATION R/F Switch (30 to 35°C (86 to 95°F)) 2010 Toyota Prius Repair Manual...

  • Page 129: (Pulse) Max. Cold

    NOTICE: If the engine keeps idling when ambient temperature is high, the compressor may automatically stop to protect the inverter circuit, and DTC B1475/75 may be stored. REPLACE COMPRESSOR WITH MOTOR ASSEMBLY SYSTEM IS OK 2010 Toyota Prius Repair Manual...
  • Page 130 CHECK CAN COMMUNICATION SYSTEM (a) Using the Techstream to check if the CAN communication system is functioning normally. Result: Result Proceed to CAN DTC is not output CAN DTC is output GO TO CAN COMMUNICATION SYSTEM 2010 Toyota Prius Repair Manual...
  • Page 131 (1) Prepare the vehicle according to the chart below. Item Condition Vehicle Doors All fully open Temperature Setting MAX COLD Blower Speed A/C switch RECIRCULATION R/F Switch (30 to 35°C (86 to 95°F)) Standard Pressure: Low pressure side 2010 Toyota Prius Repair Manual...
  • Page 132 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm , 21.3 to 35.6 psi) High pressure side 1.37 to 1.57 MPa (14 to 16 kgf/cm , 199 to 228 psi) CHARGE REFRIGERANT REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 133 (a) Using the Techstream to check if the CAN communication system is functioning normally. Result: Result Proceed to CAN DTC is not output CAN DTC is output B GO TO CAN COMMUNICATION SYSTEM A REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 134 DTC No. DTC Detection Condition Trouble Area Air conditioning harness B1497/97 Communication line error or open A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE INSPECT A/C AMPLIFIER (a) Remove the A/C amplifier with the connectors still connected. 2010 Toyota Prius Repair Manual...
  • Page 135 Power switch off Below 1 V z11-4 (B BUS) - z11-2 (BUS Power switch on 11 to 14 V (IG) Power switch on z11-3 (BUS) - z11-2 (BUS G) Pulse generation (IG) Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 136 Component with harness connected (A/C Amplifier) REPLACE A/C AMPLIFIER REPLACE AIR CONDITIONING HARNESS 2010 Toyota Prius Repair Manual...
  • Page 137 No. 2 engine wire (harness or connector B1498/98 between compressor with motor assembly and inverter with converter assembly) High-voltage power source is shut off. Electric vehicle fuse CAN communication system Hybrid control system WIRING DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 138 Be sure to carry the removed service plug grip because other workers may install it by mistake. Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 139 Only DTC P3108 is output DTCs other than P3108 are output GO TO HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (COMPRESSOR WITH MOTOR ASSEMBLY - BODY GROUND) CAUTION: Do not disconnect the connector on the high-voltage side. 2010 Toyota Prius Repair Manual...
  • Page 140 Front view of wire harness connector (to Compressor with Motor Assembly) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (COMPRESSOR WITH MOTOR ASSEMBLY - BATTERY, GROUND) (a) Turn the power switch on (IG). 2010 Toyota Prius Repair Manual...
  • Page 141 Front view of wire harness connector (to Compressor with Motor Assembly) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT CONTROL ECU - COMPRESSOR WITH MOTOR) (a) Disconnect the connector from the power management control ECU. 2010 Toyota Prius Repair Manual...
  • Page 142 (to Power Management Control ECU) Front view of wire harness connector (to Compressor with Motor Assembly) REPAIR OR REPLACE HARNESS OR CONNECTOR INSPECT ELECTRIC VEHICLE FUSE CAUTION: Be sure to wear insulated gloves. (a) Turn the power switch off. 2010 Toyota Prius Repair Manual...
  • Page 143 (e) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Item Condition Specified Condition (Tester Connection) ELECTRIC VEHICLE fuse Always Below 1 Ω (A - B) Text in Illustration Inverter with Converter Assembly 2010 Toyota Prius Repair Manual...
  • Page 144 E1-2 (PB) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to Compressor with Motor Assembly) Front view of wire harness connector (to Inverter with Converter Assembly) 2010 Toyota Prius Repair Manual...
  • Page 145 (b) Check for the DTC. Result: Result Proceed to DTC B1498/98 is not output DTC B1498/98 is output REPLACE POWER MANAGEMENT CONTROL ECU END (COMPRESSOR WITH MOTOR ASSEMBLY WAS DEFECTIVE) 2010 Toyota Prius Repair Manual...
  • Page 146 Open in plasmacluster (ion B14A1 and battery generator) circuit Harness or connector between plasmacluster (ion generator) and body ground A/C amplifier WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE PERFORM ACTIVE TEST USING TECHSTREAM (a) Connector the Techstream to the DLC3. 2010 Toyota Prius Repair Manual...
  • Page 147 OK (When troubleshooting according to the DTC) REPLACE A/C AMPLIFIER PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE CHECK HARNESS AND CONNECTOR (PLASMACLUSTER (ION GENERATOR) - BODY GROUND) (a) Disconnect the plasmacluster (ion generator) connector. 2010 Toyota Prius Repair Manual...
  • Page 148 Text in Illustration Front view of wire harness connector (to Plasmacluster (Ion Generator)) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (PLASMACLUSTER (ION GENERATOR) - A/C AMPLIFIER) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 149 Since the plasmacluster (ion generator) cannot be inspected while it is removed from the vehicle, replace the plasmacluster (ion generator) with a new or a known good one and check that the condition returns to normal. 2010 Toyota Prius Repair Manual...
  • Page 150 (b) Check for the DTC. Result: Result Proceed to DTC B14A1 is output DTC B14A1 is not output REPLACE PLASMACLUSTER (ION GENERATOR) REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 151 Harness or connector between solar sensor (automatic light control sensor) and A/C amplifier Short in driver side solar Harness or connector between solar sensor (automatic light control B14A2 sensor circuit sensor) and main body ECU Main body ECU A/C amplifier WIRING DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 152 (e) Check the value(s) by referring to the table below. Air Conditioner Measurement Diagnostic Tester Display Normal Condition Item/Range Note Solar sensor / Solar Sensor (D Solar sensor value increases as brightness Min.: 0 side) increases Max.: 255 2010 Toyota Prius Repair Manual...
  • Page 153 Power switch off Below 1 V I1-3 (CLTB) - I1-6 (CLTE) Power switch on (IG) 11 to 14 V Text in Illustration Front view of wire harness connector (to Solar Sensor (Automatic Light Control Sensor)) 2010 Toyota Prius Repair Manual...
  • Page 154 Standard Resistance: Tester Connection Condition Specified Condition L17-33 (TS) - I1-1 (NSHA) Always Below 1 Ω L17-33 (TS) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector 2010 Toyota Prius Repair Manual...
  • Page 155 NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 3 and the positive (+) lead to terminal 6 of the solar sensor (automatic light control sensor).
  • Page 156 L7-22 (CLTE) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to Main Body ECU) Front view of wire harness connector (to Solar Sensor (Automatic Light Control Sensor)) 2010 Toyota Prius Repair Manual...
  • Page 157 REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE MAIN BODY ECU 2010 Toyota Prius Repair Manual...
  • Page 158 Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. DTC No. DTC Detection Condition Trouble Area Compressor oil Refrigerant pipe line P0AA6-611 High voltage system insulation malfunction Compressor with motor assembly CAN communication system WIRING DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 159 Be sure to carry the removed service plug grip because other workers may install it by mistake. Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 160 (a) Clear the DTCs (b) Turn the power switch on (IG). (c) Prepare the vehicle according to the table below for 3 minutes. Item Condition Blower speed Temperature setting MAX COLD 2010 Toyota Prius Repair Manual...
  • Page 161 Tester Connection Condition Specified Condition E1-1 (PE) - Body ground Always 2 MΩ or higher E1-2 (PB) - Body ground Always 2 MΩ or higher Text in Illustration Component without harness connected (Compressor with Motor Assembly) 2010 Toyota Prius Repair Manual...
  • Page 162 Do not touch the high-voltage connectors or terminals for 10 minutes after the service plug grip is removed. NOTICE: Do not start the engine with the service plug grip removed because it may cause a malfunction. (h) Disconnect the connector from the compressor with motor assembly. 2010 Toyota Prius Repair Manual...
  • Page 163 NOTICE: If the results are out of the specified range, replace the compressor without operating. Text in Illustration Component without harness connected (Compressor with Motor Assembly) REPLACE AIR CONDITIONING CYCLE REPLACE COMPRESSOR WITH MOTOR ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 164 No communication with combination meter Combination meter CAN communication system Power management control ECU U0293 No communication with HV ECU INSPECTION PROCEDURE PROCEDURE GO TO CAN COMMUNICATION SYSTEM HINT: Refer to CAN Communication System NEXT END 2010 Toyota Prius Repair Manual...
  • Page 165 Inspect the fuses for circuits related to this system before performing the following inspection procedure. PROCEDURE CHECK HARNESS AND CONNECTOR (A/C CONTROL ASSEMBLY - BODY GROUND) (a) Disconnect the A/C control assembly connector. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: 2010 Toyota Prius Repair Manual...
  • Page 166 Text in Illustration Front view of wire harness connector (to A/C Control Assembly) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C CONTROL ASSEMBLY) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 167 REPLACE A/C CONTROL ASSEMBLY (a) Replace the A/C control assembly with a known good one and check if the same problem occurs again Same problem does not occur. PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE 2010 Toyota Prius Repair Manual...
  • Page 168 END (A/C CONTROL ASSEMBLY WAS DEFECTIVE) 2010 Toyota Prius Repair Manual...
  • Page 169 The blower motor is operated by signals from the A/C amplifier. Blower motor speed signals are transmitted in accordance with changes in the duty ratio. WIRING DIAGRAM 1. w/o Solar Ventilation System 2. w/ Solar Ventilation System 2010 Toyota Prius Repair Manual...
  • Page 170 (d) Enter the following menus: Body Electrical / Air Conditioner / Active Test. (e) Check the operation by referring to the table below. Air Conditioner Tester Display Test Part Control Range Diagnostic Note Blower Motor Blower motor Min.: 0, Max.: 31 2010 Toyota Prius Repair Manual...
  • Page 171 PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE CHECK HARNESS AND CONNECTOR (BLOWER MOTOR - BODY GROUND) (a) Disconnect the blower motor connector. (b) Measure the resistance according to the value(s) in the table below. 2010 Toyota Prius Repair Manual...
  • Page 172 L33-3 (+B) - Body ground Power switch off 11 to 14 V Text in Illustration Front view of wire harness connector (to Blower Motor) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (BLOWER MOTOR - A/C AMPLIFIER) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 173 (a) Reconnect the blower motor connector. (b) Measure the voltage according to the value(s) in the table below. Standard Voltage: Tester Connection Condition Specified Condition L17-23 (BLW) - Body ground Power switch off 4.5 to 5.5 V 2010 Toyota Prius Repair Manual...
  • Page 174 Front view of wire harness connector (to A/C Amplifier) REPLACE BLOWER MOTOR INSPECT A/C AMPLIFIER (a) Remove the A/C amplifier. (b) Reconnect the A/C amplifier connector. (c) Turn the power switch on (IG). (d) Set the blower speed to LO. 2010 Toyota Prius Repair Manual...
  • Page 175 Standard Resistance: Tester Connection Specified Condition 3 - 5 10 kΩ or higher 3 - 4 Below 1 Ω Below 1 Ω 3 - 5 (when battery voltage is applied to terminals 1 and 2) 2010 Toyota Prius Repair Manual...
  • Page 176 L104-5 - Body ground Always 11 to 14 V Text in Illustration Front view of wire harness connector (to Solar Ventilation Relay) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION RELAY - BODY GROUND) 2010 Toyota Prius Repair Manual...
  • Page 177 (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition L33-1 (GND) - Body ground Always Below 1 Ω Text in Illustration Front view of wire harness connector (to Blower Motor) 2010 Toyota Prius Repair Manual...
  • Page 178 Front view of wire harness connector (to Blower Motor) REPAIR OR REPLACE HARNESS OR CONNECTOR (BLOWER MOTOR - RELAY BLOCK NO. 2- CHECK HARNESS AND CONNECTOR (BLOWER MOTOR - A/C AMPLIFIER, SOLAR VENTILATION ECU) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 179 10 kΩ or higher L22-5 (BLW) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to A/C Amplifier) Front view of wire harness connector (to Solar Ventilation ECU) 2010 Toyota Prius Repair Manual...
  • Page 180 L17-23 (BLW) - Body Power switch on (IG) 4.5 to 5.5 V ground Text in Illustration Front view of wire harness connector (to A/C Amplifier) REPLACE BLOWER MOTOR INSPECT A/C AMPLIFIER (a) Remove the A/C amplifier. 2010 Toyota Prius Repair Manual...
  • Page 181 1 V/DIV., 500 μs/DIV. Power switch on (IG) Vehicle condition Blower set to LO Waveform is as shown in the illustration. HINT: The waveform varies with the blower speed. Text in Illustration Component with harness connected 2010 Toyota Prius Repair Manual...
  • Page 182 (A/C Amplifier) REPLACE A/C AMPLIFIER REPLACE BLOWER MOTOR 2010 Toyota Prius Repair Manual...
  • Page 183 The PTC heater assembly controls PTC heater lines by electric load or the amount of inverter with converter assembly (PCU) output. Therefore, troubleshooting should be performed with other electric components off. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 2010 Toyota Prius Repair Manual...
  • Page 184 (PTC Heater Assembly) REPLACE PTC HEATER ASSEMBLY CHECK HARNESS AND CONNECTOR (PTC HEATER ASSEMBLY - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition 2010 Toyota Prius Repair Manual...
  • Page 185 REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (PTC HEATER ASSEMBLY - INTEGRATION RELAY) (a) Disconnect the PTC heater assembly connector. (b) Disconnect the engine room relay block and junction block (integration relay) connector. 2010 Toyota Prius Repair Manual...
  • Page 186 Front view of wire harness connector (to Engine Room Relay Block and Junction Block (Integration Relay)) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - INTEGRATION RELAY) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 187 L17-38 (PTC2) - Body ground Always 10 kΩ or higher L17-16 (PTC3) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to A/C Amplifier) Front view of wire harness connector 2010 Toyota Prius Repair Manual...
  • Page 188 (b) Check if the same problem occurs again. Same problem does not occur. PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE END (INTEGRATION RELAY WAS DEFECTIVE) 2010 Toyota Prius Repair Manual...
  • Page 189 If there is a short in the circuit, the resulting condition is the same as if the switch were continuously depressed. Therefore, the A/C control assembly cannot be operated by the steering pad switch assembly, and the A/C control assembly will not be able to function correctly. WIRING DIAGRAM INSPECTION PROCEDURE NOTICE: 2010 Toyota Prius Repair Manual...
  • Page 190 (to Spiral with Sensor Cable Sub-assembly) CHECK HARNESS AND CONNECTOR (A/C CONTROL ASSEMBLY - SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY) CHECK HARNESS AND CONNECTOR (a) Disconnect the connector from the navigation receiver assembly*4 or radio receiver assembly*5. 2010 Toyota Prius Repair Manual...
  • Page 191 L50-6 (SWG) - Body ground*6 Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to Navigation Receiver Assembly*4, Radio Receiver Assembly*5) Front view of wire harness connector (to Radio Receiver Assembly*6) 2010 Toyota Prius Repair Manual...
  • Page 192 REPAIR OR REPLACE HARNESS OR CONNECTOR INSPECT STEERING PAD SWITCH ASSEMBLY (a) Disconnect the connector from the steering pad switch assembly. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition 2010 Toyota Prius Repair Manual...
  • Page 193 INSPECT SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY (a) Disconnect the connector from the spiral with sensor cable sub- assembly. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition 2010 Toyota Prius Repair Manual...
  • Page 194 (Spiral with Sensor Cable Sub-assembly) Steering Pad Switch Side Vehicle Side REPLACE SPIRAL WITH SENSOR CABLE SUB-ASSEMBLY CONFIRM MODEL Result: Result Proceed to w/ Navigation System w/o Navigation System REPLACE RADIO RECEIVER ASSEMBLY REPLACE NAVIGATION RECEIVER ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 195 (b) Measure the resistance according value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition L20-3 (SWO) - L52-10 (AC1) Always Below 1 Ω L20-3 (SWO) - Body ground Always 10 kΩ or higher 2010 Toyota Prius Repair Manual...
  • Page 196 Text in Illustration Front view of wire harness connector (to A/C Control Assembly) Front view of wire harness connector (to Spiral with Sensor Cable Sub-assembly) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE A/C CONTROL ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 197 If the temperature is set to MAX COOL, the fuel efficiency control due to the integration control and panel sub-assembly (ECO MODE switch) operation will be canceled. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE 2010 Toyota Prius Repair Manual...
  • Page 198 PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE CHECK HARNESS AND CONNECTOR (ECO MODE SWITCH - BODY GROUND) (a) Disconnect the connector from the integration control and panel sub- assembly (ECO MODE switch). 2010 Toyota Prius Repair Manual...
  • Page 199 Tester Connection Condition Condition ECO MODE switch off L78-2 (ECU) - L78-5 10 kΩ or higher (when switch is not pressed) ECO MODE switch on L78-2 (ECU) - L78-5 Below 1 Ω (when switch is pressed) 2010 Toyota Prius Repair Manual...
  • Page 200 10 kΩ or higher Text in Illustration Front view of wire harness connector (to A/C Amplifier) Front view of wire harness connector (to Integration Control and Panel Sub-assembly (ECO MODE Switch)) REPAIR OR REPLACE HARNESS OR CONNECTOR 2010 Toyota Prius Repair Manual...
  • Page 201 REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 202 Inspect the fuses for circuits related to this system before performing the following inspection procedure. HINT: Turn the power switch on (IG) before inspection. Check the IG1 NO. 1 relay or auxiliary battery if the power source does not change to on (IG). PROCEDURE 2010 Toyota Prius Repair Manual...
  • Page 203 Component with harness connected (A/C Amplifier) CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BATTERY) PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BATTERY) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 204 (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition L17-14 (GND) - Body ground Always Below 1 Ω Text in Illustration Front view of wire harness connector (to A/C Amplifier) 2010 Toyota Prius Repair Manual...
  • Page 205 REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 206 WIRING DIAGRAM INSPECTION PROCEDURE NOTICE: Inspect the fuses for circuits related to this system before performing the following inspection procedure. PROCEDURE CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BATTERY) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 207 11 to 14 V Text in Illustration Front view of wire harness connector (to A/C Amplifier) REPAIR OR REPLACE HARNESS OR CONNECTOR CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BODY GROUND) (a) Disconnect the A/C amplifier connector. 2010 Toyota Prius Repair Manual...
  • Page 208 L17-14 (GND) - Body ground Always Below 1 Ω Text in Illustration Front view of wire harness connector (to A/C Amplifier) REPAIR OR REPLACE HARNESS OR CONNECTOR PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE 2010 Toyota Prius Repair Manual...
  • Page 209 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 210 ILLUSTRATION 2010 Toyota Prius Repair Manual...
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  • Page 218 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 219 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 220 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 221 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 222 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 223 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 224 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 225 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 226 ILLUSTRATION 2010 Toyota Prius Repair Manual...
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  • Page 228 2010 Toyota Prius Repair Manual...
  • Page 229 12. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH 13. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 14. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 15. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 16. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 230 (a) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose. Do not apply excessive force to the inlet heater water hose. Prepare a drain pan or cloth in case the coolant leaks. 2010 Toyota Prius Repair Manual...
  • Page 231 32. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP LH 33. REMOVE INSTRUMENT PANEL FINISH PANEL END LH 34. REMOVE NO. 1 SIDE DEFROSTER NOZZLE 35. REMOVE NO. 2 INSTRUMENT PANEL REGISTER 36. REMOVE GLOVE COMPARTMENT DOOR 2010 Toyota Prius Repair Manual...
  • Page 232 51. REMOVE UPPER CONSOLE PANEL (w/ Power Outlet Socket) 52. REMOVE CONSOLE BOX CARPET 53. REMOVE REAR CONSOLE BOX ASSEMBLY (w/ Power Outlet Socket) 54. REMOVE REAR CONSOLE BOX ASSEMBLY (w/o Power Outlet Socket) 55. REMOVE ELECTRICAL KEY OSCILLATOR 2010 Toyota Prius Repair Manual...
  • Page 233 75. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 76. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY 77. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedure for the RH side and LH side. 78. REMOVE COWL SIDE TRIM BOARD RH 2010 Toyota Prius Repair Manual...
  • Page 234 Brush Type Motor: for Brushless Type Motor: 96. REMOVE REAR NO. 2 AIR DUCT (w/ Rear Air Duct) (a) Disengage each claw to open the 2 door scuff plate clamps as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 235 (d) Disengage the 2 claws and remove the rear No. 2 air duct. 97. REMOVE REAR NO. 3 AIR DUCT (w/ Rear Air Duct) (a) Disengage each claw to open the 2 door scuff plate clamps as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 236 (d) Disengage the 2 claws and remove the rear No. 3 air duct. 98. REMOVE REAR NO. 1 AIR DUCT (w/ Rear Air Duct) (a) Disengage the 4 claws and remove the rear No. 1 air duct. 99. REMOVE NO. 3 SIDE DEFROSTER NOZZLE DUCT 2010 Toyota Prius Repair Manual...
  • Page 237 When disconnecting any airbag connector, take care not to damage the airbag wire harness. (d) Remove the screw. (e) Remove the 2 bolts and disconnect the 2 earth wires. (f) Disconnect each connector. (g) Disengage each clamp and claw. 2010 Toyota Prius Repair Manual...
  • Page 238 Text in Illustration Center Airbag Sensor Connector Screw Bolt Earth Wire (h) Remove the screw. 2010 Toyota Prius Repair Manual...
  • Page 239 (a) Remove the 3 screws <A>. (b) Remove the bolt and disconnect the earth wire. (c) Disconnect each connector. (d) Disengage each clamp. (e) Remove the screw <B> and 2 nuts from the computer integration box RH. 2010 Toyota Prius Repair Manual...
  • Page 240 Text in Illustration Screw <A> Bolt Earth Wire Screw <B> Computer Integration Box RH (f) Remove the screw. 2010 Toyota Prius Repair Manual...
  • Page 241 103. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY (a) Disengage the clamp. (b) Disengage the 6 claws and remove the lower defroster nozzle assembly. 104. REMOVE NO. 3 AIR DUCT SUB-ASSEMBLY (a) Remove the 2 nuts and No. 3 air duct sub-assembly. 2010 Toyota Prius Repair Manual...
  • Page 242 105. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Disengage each clamp. (b) Remove the 9 bolts and instrument panel reinforcement assembly. 2010 Toyota Prius Repair Manual...
  • Page 243 When disassembling the air conditioning unit, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Disengage the cooler drain hose. 2010 Toyota Prius Repair Manual...
  • Page 244 (b) Remove the bolt, nut and air conditioning unit assembly. 2010 Toyota Prius Repair Manual...
  • Page 245 4. REMOVE AIR CONDITIONING DUCT SUB-ASSEMBLY (a) Disengage the 2 claws and remove the air conditioning duct sub- assembly. 5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY (a) Disconnect each connector. (b) Disengage each clamp and remove the air conditioning harness assembly. 2010 Toyota Prius Repair Manual...
  • Page 246 (a) Remove the 3 screws and air outlet control servo motor sub-assembly. 7. REMOVE AIR MIX CONTROL SERVO MOTOR SUB-ASSEMBLY (a) Remove the 3 screws and air mix control servo motor sub-assembly. 8. REMOVE QUICK HEATER ASSEMBLY (a) Disengage each clamp. 2010 Toyota Prius Repair Manual...
  • Page 247 (b) Remove the heater radiator unit sub-assembly as shown in the illustration. NOTICE: Prepare a drain pan or cloth in case the cooling water leaks. 10. REMOVE CONSOLE MOUNTING BRACKET LH (a) Remove the screw and console mounting bracket LH. 2010 Toyota Prius Repair Manual...
  • Page 248 (b) Disengage the 2 guides and remove the air conditioning amplifier assembly as shown in the illustration. 12. REMOVE CONSOLE MOUNTING BRACKET RH (a) Disengage the 2 claws and remove the console mounting bracket RH. 13. REMOVE DRAIN COOLER HOSE (a) Remove the drain cooler hose as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 249 (a) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts and cooler expansion valve. 15. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY (a) Remove the packing. NOTICE: Remove the packing carefully because it will be reused. (b) Remove the 4 screws. 2010 Toyota Prius Repair Manual...
  • Page 250 (c) Disengage the 4 claws and remove the lower heater case. (d) Disengage the clamp and remove the cooler evaporator sub-assembly with the No. 1 cooler thermistor. (e) Remove the 2 O-rings from the cooler evaporator sub-assembly. 16. REMOVE NO. 1 COOLER THERMISTOR 2010 Toyota Prius Repair Manual...
  • Page 251 ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (c) Engage the clamp and install the cooler evaporator sub-assembly with the No. 1 cooler thermistor. HINT: Completely cover the tube with the grommet. (d) Engage the 4 claws. 2010 Toyota Prius Repair Manual...
  • Page 252 (a) Using a 4 mm hexagon wrench, install the cooler expansion valve with the 2 hexagon bolts. Torque: 3.5 N·m (36 kgf·cm, 31in·lbf) 4. INSTALL DRAIN COOLER HOSE (a) Install the drain cooler hose as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 253 (a) Engage the 2 guides to install the air conditioning amplifier assembly as shown in the illustration. (b) Install the screw. 7. INSTALL CONSOLE MOUNTING BRACKET LH (a) Install the console mounting bracket LH with the screw. 2010 Toyota Prius Repair Manual...
  • Page 254 (a) Install the heater radiator unit sub-assembly as shown in the illustration. (b) Install the clamp with the screw. Text in Illustration Clamp 9. INSTALL QUICK HEATER ASSEMBLY (a) Install the quick heater assembly as shown in the illustration. (b) Install the 2 screws. 2010 Toyota Prius Repair Manual...
  • Page 255 (a) Using the reference point, install the air outlet control servo motor sub- assembly with the 3 screws. Text in Illustration Reference Point 12. INSTALL AIR CONDITIONING HARNESS ASSEMBLY (a) Connect each connector. (b) Engage each clamp to install the air conditioning harness assembly. 2010 Toyota Prius Repair Manual...
  • Page 256 14. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (a) Engage the 2 claws to install the No. 1 air duct sub-assembly. 15. INSTALL BLOWER ASSEMBLY 16. INSTALL ID CODE BOX (IMMOBILISER CODE ECU) (w/ Engine Immobiliser System) 2010 Toyota Prius Repair Manual...
  • Page 257 (a) Install the instrument panel reinforcement assembly with the 6 bolts <A>. (b) Install the air conditioning unit assembly with the 3 bolts <B> Bolt <B> - Torque: 9.8 N·m (100 kgf·cm, 87in·lbf) HINT: Tighten the bolts in the order shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 258 (c) Engage each clamp. 2010 Toyota Prius Repair Manual...
  • Page 259 (a) Install the No. 3 air duct sub-assembly with the 2 nuts. Torque: 9.8 N·m (100 kgf·cm, 87in·lbf) 5. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY (a) Engage the 6 claws and remove the lower defroster nozzle assembly. 2010 Toyota Prius Repair Manual...
  • Page 260 (a) Install the defroster nozzle assembly as shown in the illustration. (b) Engage the 3 claws. 7. INSTALL NO. 2 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (a) Install the No. 2 instrument panel brace sub-assembly with the screw. Torque: 4.0 N·m (41 kgf·cm, 35in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 261 (c) Install the screw <B> and 2 nuts to the computer integration box RH. (d) Engage each clamp. (e) Connect each connector. (f) Install the 3 screws <A>. (g) Install the bolt and connect the earth wire. Torque: 8.4 N·m (86 kgf·cm, 74in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 262 Bolt Earth Wire Screw <B> Computer Integration Box RH 8. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY (a) Install the No. 1 instrument panel brace sub-assembly with the screw. Torque: 4.0 N·m (41 kgf·cm, 35in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 263 (g) Check that there is no looseness in the installation parts of the center airbag sensor assembly. (h) Connect each connector. (i) Engage each clamp and claw. (j) Install the screw. (k) Install the 2 bolts and connect the 2 earth wires. Torque: 8.4 N·m (86 kgf·cm, 74in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 264 Text in Illustration Center Airbag Sensor Connector Screw Bolt Earth Wire Waterproof Sheet 9. INSTALL NO. 3 SIDE DEFROSTER NOZZLE DUCT (a) Install the No. 3 side defroster nozzle duct with the clip. 2010 Toyota Prius Repair Manual...
  • Page 265 (a) Engage the 4 claws to install the rear No. 1 air duct. 11. INSTALL REAR NO. 3 AIR DUCT (w/ Rear Air Duct) (a) Engage the 2 claws to install the rear No. 3 air duct. (b) Engage the 2 claws and install the clip. 2010 Toyota Prius Repair Manual...
  • Page 266 (d) Engage each claw to close the door scuff plate clamps as shown in the illustration. 12. INSTALL REAR NO. 2 AIR DUCT (w/ Rear Air Duct) (a) Engage the 2 claws to install the rear No. 2 air duct. (b) Engage the 2 claws and install the clip. 2010 Toyota Prius Repair Manual...
  • Page 267 17. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY 18. INSTALL PUSH ROD PIN 19. INSTALL BRAKE PEDAL RETURN SPRING 20. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER 21. INSTALL STOP LIGHT SWITCH ASSEMBLY 22. INSTALL DRIVER SIDE JUNCTION BLOCK ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 268 38. INSTALL UPPER STEERING COLUMN COVER 39. INSTALL LOWER STEERING COLUMN COVER 40. INSTALL STEERING WHEEL ASSEMBLY 41. INSTALL STEERING PAD 42. INSTALL LOWER NO. 3 STEERING WHEEL COVER 43. INSTALL LOWER NO. 2 STEERING WHEEL COVER 2010 Toyota Prius Repair Manual...
  • Page 269 Use the same procedure for the RH side and LH side. 63. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY 64. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH 65. INSTALL FRONT PILLAR GARNISH RH HINT: 2010 Toyota Prius Repair Manual...
  • Page 270 86. INSTALL LOWER CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 87. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY 88. CONNECT OUTLET HEATER WATER HOSE (a) Using pliers, grip the claws of the clip and slide the clip to connect the 2010 Toyota Prius Repair Manual...
  • Page 271 Compressor oil: ND-OIL 11 or equivalent (c) Install the O-ring on the air conditioning tube and accessory assembly. NOTICE: Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects. 2010 Toyota Prius Repair Manual...
  • Page 272 (f) Insert the pipe joint into the fitting hole securely and tighten the bolt. Torque: 9.8 N·m (100 kgf·cm, 87in·lbf) 92. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 93. INSTALL COWL BODY MOUNTING REINFORCEMENT LH 2010 Toyota Prius Repair Manual...
  • Page 273 108. INSPECT FOR REFRIGERANT LEAK 109. INSPECT FOR COOLANT LEAK (for Engine) 110. INSPECT SHIFT LEVER 111. INSPECT STEERING PAD (a) Inspect the steering pad 112. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light 2010 Toyota Prius Repair Manual...
  • Page 274 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 275 2010 Toyota Prius Repair Manual...
  • Page 276 REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER 2. REMOVE FRONT BUMPER ASSEMBLY 3. REMOVE AMBIENT TEMPERATURE SENSOR (a) Disconnect the connector. (b) Disengage the clamp to remove the ambient temperature sensor. 2010 Toyota Prius Repair Manual...
  • Page 277 When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the ambient temperature sensor. 2010 Toyota Prius Repair Manual...
  • Page 278 2. INSTALL FRONT BUMPER ASSEMBLY 3. INSTALL RADIATOR SUPPORT OPENING COVER 4. ADD WINDSHIELD WASHER FLUID (w/ Headlight Cleaner System) 5. ADJUST FOG LIGHT AIMING HINT: Refer to the procedure for Adjust Fog Light Aiming 2010 Toyota Prius Repair Manual...
  • Page 279 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 280 2010 Toyota Prius Repair Manual...
  • Page 281 (a) Remove the screw and disconnect the quick heater connector. (b) Disconnect the connector and disengage each clamp. (c) Disengage the 3 screws and guide, and remove the blower assembly. Text in Illustration Quick Heater Connector 2010 Toyota Prius Repair Manual...
  • Page 282 (a) Disengage the claw and guide, and remove the air filter case as shown in the illustration. 3. REMOVE CLEAN AIR FILTER (a) Remove the clean air filter as shown in the illustration. 4. REMOVE FRONT BLOWER MOTOR SUB-ASSEMBLY (w/o Solar Ventilation System) 2010 Toyota Prius Repair Manual...
  • Page 283 5. REMOVE FRONT BLOWER MOTOR SUB-ASSEMBLY (w/ Solar Ventilation System) (a) Remove the 3 screws and front blower motor sub-assembly. NOTICE: Do not remove the front blower motor sub-assembly if it has been damaged or impacted. 2010 Toyota Prius Repair Manual...
  • Page 284 3. INSTALL CLEAN AIR FILTER (a) Install the clean air filter as shown in the illustration. 4. INSTALL AIR FILTER CASE (a) Engage the guide and claw to install the air filter case as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 285 5. INSTALL AIR INLET CONTROL SERVO MOTOR SUB-ASSEMBLY (a) Install the air inlet control servo motor sub-assembly with the 2 screws. 2010 Toyota Prius Repair Manual...
  • Page 286 (d) Engage each clamps. (e) Install the screw and connect the quick heater connector. Text in Illustration Quick Heater Connector 2. INSTALL AIR CONDITIONING UNIT ASSEMBLY HINT: Refer to the procedure for Install Air Conditioning Unit Assembly 2010 Toyota Prius Repair Manual...
  • Page 287 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 288 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 289 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 290 2010 Toyota Prius Repair Manual...
  • Page 291 (b) Check the terminal voltage CAUTION: Wear insulating gloves. (c) Install the inverter cover with the 9 bolts to the inverter with converter assembly. Torque: 8.0 N·m (82 kgf·cm, 71in·lbf) CAUTION: 2010 Toyota Prius Repair Manual...
  • Page 292 Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. 14. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the suction hose sub-assembly from the electric inverter compressor. 2010 Toyota Prius Repair Manual...
  • Page 293 Wear insulated gloves when performing the procedures. NOTICE: Insulate the connector by sealing it with tape. Text in Illustration Green-colored Lock (b) Disconnect the connector <B>. (c) Remove the 3 bolts and electric inverter compressor. 2010 Toyota Prius Repair Manual...
  • Page 294 2 MΩ or higher E1-2 (PB) - Body ground Always 2 MΩ or higher Text in Illustration Component without harness connected (Compressor with motor assembly) If the resistance is not as specified, replace the compressor with motor assembly. 2010 Toyota Prius Repair Manual...
  • Page 295 2010 Toyota Prius Repair Manual...
  • Page 296 (a) Temporarily install the electric inverter compressor with the 3 bolts. (b) Install the electric inverter compressor with the 3 bolts. Torque: 25 N·m (250 kgf·cm, 18ft·lbf) NOTICE: Tighten the bolts in the order shown in the illustration to install the 2010 Toyota Prius Repair Manual...
  • Page 297 ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N·m (100 kgf·cm, 87in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 298 Torque: 9.8 N·m (100 kgf·cm, 87in·lbf) 5. CONNECT NO. 2 RADIATOR HOSE (a) Using pliers, grip the claws of the clip and slide the clip to install the No. 2 radiator hose. 2010 Toyota Prius Repair Manual...
  • Page 299 12. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) 13. CHARGE WITH REFRIGERANT 14. WARM UP COMPRESSOR 15. INSPECT FOR REFRIGERANT LEAK 16. INSTALL NO. 1 ENGINE UNDER COVER 17. INSTALL INLET AIR CLEANER ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 300 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 301 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 302 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 303 2010 Toyota Prius Repair Manual...
  • Page 304 (b) If any cooler condenser assembly fins are bent, straighten them using a screwdriver or pliers. 2. INSPECT FOR REFRIGERANT LEAK (a) Using a halogen leak detector, check pipe joints for refrigerant leaks. (b) If refrigerant leak is detected in a joint, check the torque of the joint. 2010 Toyota Prius Repair Manual...
  • Page 305 (a) w/o Dynamic Radar Cruise Control System: (1) Remove the 3 bolts and millimeter wave radar sensor bracket. (b) w/ Dynamic Radar Cruise Control System: (1) Remove the bolt and millimeter wave radar sensor bracket. 2010 Toyota Prius Repair Manual...
  • Page 306 (a) Remove the bolt and disconnect the air conditioning tube and accessory assembly. (b) Remove the O-ring from the air conditioning tube and accessory assembly. NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter. 2010 Toyota Prius Repair Manual...
  • Page 307 16. REMOVE NO. 2 FAN SHROUD 17. REMOVE COOLER CONDENSER ASSEMBLY (a) Remove the cooler condenser assembly with hybrid radiator assembly. (b) Remove the 4 bolts and cooler condenser assembly from the hybrid radiator assembly. 2010 Toyota Prius Repair Manual...
  • Page 308 2010 Toyota Prius Repair Manual...
  • Page 309 2. REMOVE COOLER DRYER (a) Using a 14 mm straight hexagon wrench, remove the cap from the modulator. Text in Illustration *1 14 mm Straight Hexagon Wrench *2 Modulator (b) Using pliers, remove the cooler dryer. 2010 Toyota Prius Repair Manual...
  • Page 310 2010 Toyota Prius Repair Manual...
  • Page 311 Text in Illustration *1 14 mm Straight Hexagon Wrench *2 Modulator 2. INSTALL COOLER CONDENSER CUSHION (a) for LH Side: (1) Install the cooler condenser cushion. 2010 Toyota Prius Repair Manual...
  • Page 312 (b) for RH Side: (1) Install the cooler condenser cushion. 2010 Toyota Prius Repair Manual...
  • Page 313 3. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY 4. INSTALL NO. 1 INVERTER BRACKET 5. CONNECT NO. 7 INVERTER COOLING HOSE (a) Using pliers, grip the claws of the clip and slide the clip to connect the No. 7 inverter cooling hose. 2010 Toyota Prius Repair Manual...
  • Page 314 ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Install the air conditioning tube and accessory assembly on the cooler condenser assembly with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48in·lbf) 2010 Toyota Prius Repair Manual...
  • Page 315 (1) Install the millimeter wave radar sensor bracket with the 3 bolts. Torque: 6.2 N·m (63 kgf·cm, 55in·lbf) NOTICE: Tighten the bolts in the order shown in the illustration to install the millimeter wave radar sensor bracket. (b) w/ Dynamic Radar Cruise Control System: 2010 Toyota Prius Repair Manual...
  • Page 316 18. ADD COOLANT (for Inverter) 19. WARM UP COMPRESSOR 20. INSPECT FOR REFRIGERANT LEAK 21. INSPECT FOR COOLANT LEAK (for Inverter) 22. ADJUST FOG LIGHT AIMING HINT: Refer to the procedure for Adjust Fog Light Aiming 2010 Toyota Prius Repair Manual...
  • Page 317 23. ADJUST HOOD SUB-ASSEMBLY HINT: Refer to the procedure for Adjust Hood Sub-assembly 24. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) 25. INSTALL RADIATOR SUPPORT OPENING COVER 2010 Toyota Prius Repair Manual...
  • Page 318 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 319 (c) Remove the 3 screws and front blower motor sub-assembly. NOTICE: Do not remove the front blower motor sub-assembly if it has been damaged or impacted. 4. REMOVE FRONT BLOWER MOTOR SUB-ASSEMBLY (w/ Solar Ventilation System) (a) Remove the quick heater connector screw. 2010 Toyota Prius Repair Manual...
  • Page 320 (b) Disengage the clamp and disconnect the connector. (c) Remove the 3 screws and front blower motor sub-assembly. NOTICE: Do not remove the front blower motor sub-assembly if it has been damaged or impacted. 2010 Toyota Prius Repair Manual...
  • Page 321 (a) Install the front blower motor sub-assembly with the 3 screws. NOTICE: Do not install the front blower motor sub-assembly if it has been damaged or impacted. (b) Engage the clamp and connect the connector. 2010 Toyota Prius Repair Manual...
  • Page 322 (c) Install the quick heater connector screw. 4. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 2010 Toyota Prius Repair Manual...
  • Page 323 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 324 2010 Toyota Prius Repair Manual...
  • Page 325 Refer to the procedure for Remove Air Conditioning Unit Assembly 2. REMOVE BLOWER ASSEMBLY 3. REMOVE COOLER EXPANSION VALVE 4. REMOVE COOLER EVAPORATOR SUB-ASSEMBLY 5. REMOVE NO. 1 COOLER THERMISTOR (a) Remove the No. 1 cooler thermistor. 2010 Toyota Prius Repair Manual...
  • Page 326 When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the evaporator temperature sensor. 2010 Toyota Prius Repair Manual...
  • Page 327 "b". 2. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY 3. INSTALL COOLER EXPANSION VALVE 4. INSTALL BLOWER ASSEMBLY 5. INSTALL AIR CONDITIONING UNIT ASSEMBLY HINT: Refer to the procedure for Install Air Conditioning Unit Assembly 2010 Toyota Prius Repair Manual...
  • Page 328 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 329 2. REMOVE NO. 3 HEATER TO REGISTER DUCT 3. REMOVE PLASMACLUSTER WITH BRACKET (a) Disconnect the connector. (b) Remove the 2 screws and plasmacluster with bracket. 4. REMOVE PLASMACLUSTER (a) Remove the 2 screws and plasmacluster from the 2 brackets. 2010 Toyota Prius Repair Manual...
  • Page 330 Torque: 4.0 N·m (41 kgf·cm, 35in·lbf) (b) Connect the connector. 3. INSTALL NO. 3 HEATER TO REGISTER DUCT 4. INSTALL UPPER INSTRUMENT PANEL ASSEMBLY HINT: Refer to the procedure for Install Upper Instrument Panel Assembly 2010 Toyota Prius Repair Manual...
  • Page 331 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 332 Refer to 5 and 6 excessive compressor inlet and outlet Immediately after air 1. Recover refrigerant conditioning is turned 2. Evacuate the AC Excessive off, refrigerant system and recharge remains clear with a proper 2010 Toyota Prius Repair Manual...
  • Page 333 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm , 21 to 36 psi) High 1.37 to 1.57 MPa (13.9 to 16.0 kgf/cm , 199 to 228 psi) (2) Moisture is present in the refrigeration system. 2010 Toyota Prius Repair Manual...
  • Page 334 0, then it continuously system leaking will be necessary to evacuate Insufficient cooling the system after repairing the performance leak (4) Poor circulation of refrigerant Corrective Symptom Probable Cause Diagnosis Action 2010 Toyota Prius Repair Manual...
  • Page 335 (6) Refrigerant is overcharged or cooling effectiveness of condenser is insufficient. Symptom Probable Cause Diagnosis Corrective Action Pressure is too Unable to develop Excessive refrigerant 1. Clean condenser 2010 Toyota Prius Repair Manual...
  • Page 336 2. Evacuate the system and Insufficient vacuum is too hot to touch recharge it with new or system purging Bubbles can be seen purified refrigerant through sight glass (8) Expansion valve malfunction Corrective Symptom Probable Cause Diagnosis Action 2010 Toyota Prius Repair Manual...
  • Page 337 Pressure is too high on both low Low compression and high pressure sides Internal leak in Leak from a damaged valve, Replace Pressure is too low on high compressor or parts may be broken compressor pressure side Gauge readings (Reference) 2010 Toyota Prius Repair Manual...
  • Page 338 2010 Toyota Prius Repair Manual...
  • Page 339 (d) Recover the refrigerant from the A/C system using a refrigerant recovery unit. 2. CHARGE WITH REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge with refrigerant HFC-134a (R134a). Standard: 470 g (16.6 oz.) SST: 09985-20010 2010 Toyota Prius Repair Manual...
  • Page 340 (including the compressor), to prevent damage to the compressor. 4. INSPECT FOR REFRIGERANT LEAK (a) After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector. (b) Carry out the test under the following conditions: 2010 Toyota Prius Repair Manual...
  • Page 341 Insert the halogen leak detector sensor into the unit and perform the test. (f) Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test. 2010 Toyota Prius Repair Manual...
  • Page 342 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 343 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 344 ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 345 2010 Toyota Prius Repair Manual...
  • Page 346 18. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL ASSEMBLY 19. REMOVE NO. 1 SWITCH HOLE BASE 20. REMOVE ROOM TEMPERATURE SENSOR (a) Disengage the 2 claws and remove the room temperature sensor from the No. 1 switch hole base. 2010 Toyota Prius Repair Manual...
  • Page 347 2010 Toyota Prius Repair Manual...
  • Page 348 When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). If the resistance is not as specified, replace the room temperature sensor. 2010 Toyota Prius Repair Manual...
  • Page 349 12. INSTALL REAR CONSOLE BOX ASSEMBLY (w/ Power Outlet Socket) 13. INSTALL REAR CONSOLE BOX ASSEMBLY (w/o Power Outlet Socket) 14. INSTALL CONSOLE BOX CARPET 15. INSTALL UPPER CONSOLE PANEL (w/ Power Outlet Socket) 16. INSTALL REAR CONSOLE BOX POCKET (w/ Power Outlet Socket) 2010 Toyota Prius Repair Manual...
  • Page 350 17. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY 18. INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH 19. INSTALL LOWER CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY 20. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY 21. INSPECT SHIFT LEVER 2010 Toyota Prius Repair Manual...
  • Page 351 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 352 1. REMOVE UPPER INSTRUMENT PANEL ASSEMBLY HINT: Refer to the procedure for Remove Upper Instrument Panel Assembly 2. REMOVE SOLAR SENSOR (a) Disconnect the connector. (b) Disengage the 2 claws and remove the solar sensor as shown in the illustration. 2010 Toyota Prius Repair Manual...
  • Page 353 11 to 14 V Text in Illustration Front view of wire harness connector (to Solar Sensor) If the voltage is not as specified, repair or replace the wire harness or connector. (c) Reconnect the solar sensor connector. 2010 Toyota Prius Repair Manual...
  • Page 354 NOTICE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 6 and the negative (-) lead to terminal 1 of the solar sensor.
  • Page 355 (a) Engage the 2 claws to install the solar sensor as shown in the illustration. (b) Connect the connector. 2. INSTALL UPPER INSTRUMENT PANEL ASSEMBLY HINT: Refer to the procedure for Install Upper Instrument Panel Assembly 2010 Toyota Prius Repair Manual...
  • Page 356 COMPONENTS ILLUSTRATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 357 2010 Toyota Prius Repair Manual...
  • Page 358 9. REMOVE RADIO RECEIVER WITH BRACKET (w/o Navigation System) 10. REMOVE NAVIGATION RECEIVER WITH BRACKET (w/ Navigation System) 11. REMOVE AIR CONDITIONING CONTROL ASSEMBLY 12. REMOVE SOLAR VENTILATION ECU (a) Remove the bolt. (b) Disconnect the connector to remove the solar ventilation ECU. 2010 Toyota Prius Repair Manual...
  • Page 359 When disconnecting the cable, some systems need to be initialized after the cable is reconnected 10. INSTALL REAR NO. 3 FLOOR BOARD 11. INSTALL REAR DECK FLOOR BOX 12. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) 2010 Toyota Prius Repair Manual...
  • Page 360 COMPONENTS ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 361 1. REMOVE FRONT DOOR SCUFF PLATE LH 2. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH 3. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY 4. REMOVE SOLAR VENTILATION SWITCH (a) Disengage the 2 claws and remove the solar ventilation switch. 2010 Toyota Prius Repair Manual...
  • Page 362 9 (SW+) - 6 (SW-) Solar ventilation switch: off 10 kΩ or higher 9 (SW+) - 6 (SW-) Solar ventilation switch: on Below 1 Ω Text in Illustration Component without harness connected (Solar Ventilation Switch) If the resistance is not as specified, replace the solar ventilation switch. 2010 Toyota Prius Repair Manual...
  • Page 363 1. INSTALL SOLAR VENTILATION SWITCH (a) Engage the 2 claws to install the solar ventilation switch. 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY 3. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH 4. INSTALL FRONT DOOR SCUFF PLATE LH 2010 Toyota Prius Repair Manual...
  • Page 364 Depending on the strength of the sunlight when the outside temperature is low, the cabin temperature may become low because of the cool air drawn into the cabin due to solar ventilation system operation. 2010 Toyota Prius Repair Manual...
  • Page 365 HINT: The moon roof glass assembly (solar panel) always generates electricity when exposed to light. When exposed to a light source such as sunlight, approximately 3.6 A and 22 V will be generated. 2010 Toyota Prius Repair Manual...
  • Page 366 PARTS LOCATION ILLUSTRATION 2010 Toyota Prius Repair Manual...
  • Page 367 SYSTEM DIAGRAM 2010 Toyota Prius Repair Manual...
  • Page 368 (2) When the solar ventilation switch is turned on after the power switch is turned off: The blower motor will be activated and start ventilating the cabin approximately 10 minutes after the solar ventilation switch is turned on. HINT: 2010 Toyota Prius Repair Manual...
  • Page 369 (1) When the solar ventilation switch is turned off or the power switch is turned on (IG), the solar ventilation system will stop operating. HINT: After the power switch is turned on (IG), both the inlets and outlets return to the mode that they were in before the power switch was turned off. 2010 Toyota Prius Repair Manual...
  • Page 370 Air inlet control servo Switches the inlets to fresh air mode based on signals from the A/C amplifier. motor Air outlet control servo Switches the outlets to face mode based on signals from the A/C amplifier. motor 2010 Toyota Prius Repair Manual...
  • Page 371 Proceed to DTC is not output. DTC is output. B GO TO RELEVANT SYSTEM PROBLEM SYMPTOMS TABLE (a) Refer to Problem Symptoms Table Result: Result Proceed to Fault is not listed in Problem Symptoms Table 2010 Toyota Prius Repair Manual...
  • Page 372 Fault is listed in Problem Symptoms Table B Go to step 5 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Terminals of ECU (b) Data List / Active Test (c) Operation Check (d) Inspection NEXT ADJUST, REPAIR OR REPLACE NEXT END 2010 Toyota Prius Repair Manual...
  • Page 373 Solar panel voltage / System operation Actual generated Solar conditions reference Variable, 10V les, 10V-11V, 11V-12V, 12V-13V, 13V- voltage Voltage 14V, 14V-15V, 15V-16V, 16V-17V, 17V-18V, 18V- displayed table are met 19V, 19V-20V, 20V-21V, 21V-22V, 22V-23V or 23V 2010 Toyota Prius Repair Manual...
  • Page 374 Perform the operation according to the following procedure with the power switch on (IG) and the solar ventilation switch off. (1) Check that the Solar Voltage value in the Data List is 10 V or higher. 2010 Toyota Prius Repair Manual...
  • Page 375 When the solar ventilation switch is turned off, the blower motor will stop and when the solar ventilation switch is turned on, the blower motor will operate. When the power switch is turned off, the solar ventilation system returns to normal control. 2010 Toyota Prius Repair Manual...
  • Page 376 2010 Toyota Prius Repair Manual...
  • Page 377 IG signal Circuit The blower motor operates by itself or the motor speed changes arbitrarily. Solar ventilation ECU Conditions listed in System Operation Conditions Cabin is smelly or damp. Reference Table have not been met 2010 Toyota Prius Repair Manual...
  • Page 378 Solar ventilation switch P - W-B L22-1 (GND) status signal Solar ventilation switch: on Below 1 V Pulse L22-17 (SIND) - Solar ventilation ECU Power switch on (IG) L - W-B generation L22-1 (GND) status signal 2010 Toyota Prius Repair Manual...
  • Page 379 L22-17 (SIND) - L22-1 (GND) Tool Setting 1 V/DIV., 100 ms/DIV. Power switch on (IG) Vehicle Condition SBI terminal: 7 V or higher Solar ventilation system: off HINT: The waveform varies with the communication content. 2. A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 380 ECU side) / Ventilation Switch Status ON: Solar OFF or ON ventilation switch on Solar ventilation ECU IG status / When OFF is displayed, a Solar IG Status OFF: Power malfunction in the solar 2010 Toyota Prius Repair Manual...
  • Page 381 (d) Enter the following menus: Body Electrical / Air Conditioner / Active Test. (e) Check the operation by referring to the table below. Air Conditioner Tester Display Test Part Control Range Diagnostic Note Blower Motor Blower motor Min.: 0, Max.: 31 2010 Toyota Prius Repair Manual...
  • Page 382 If the Data List items are not displayed, inspect the communication circuit between the solar ventilation ECU and A/C amplifier PROCEDURE READ VALUE USING TECHSTREAM (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). (c) Turn the Techstream on. 2010 Toyota Prius Repair Manual...
  • Page 383 PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION ECU - BATTERY) (a) Disconnect the solar ventilation ECU connector. 2010 Toyota Prius Repair Manual...
  • Page 384 L22-25 (IG) - Body ground Power switch on (IG) 11 to 14 V Text in Illustration Front view of wire harness connector (to Solar Ventilation ECU) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE SOLAR VENTILATION ECU 2010 Toyota Prius Repair Manual...
  • Page 385 Changes its speed according to the amount of sunlight received by the moon roof glass assembly (solar panel). WIRING DIAGRAM INSPECTION PROCEDURE NOTICE: Inspect the fuses for circuits related to this system before performing the following inspection procedure. 2010 Toyota Prius Repair Manual...
  • Page 386 (a) Remove the solar ventilation relay. (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Specified Condition 3 - 5 10 kΩ or higher 3 - 4 Below 1 Ω 2010 Toyota Prius Repair Manual...
  • Page 387 Solar ventilation switch off Power switch off Solar ventilation switch on L104-4 - Body ground 1 to 28 V (System operation conditions reference table met Text in Illustration Front view of wire harness connector (to Solar Ventilation Relay) 2010 Toyota Prius Repair Manual...
  • Page 388 Standard Resistance: Tester Connection Condition Specified Condition L22-5 (BLW) - L33-2 (SI) Always Below 1 Ω L22-5 (BLW) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector 2010 Toyota Prius Repair Manual...
  • Page 389 Waveform is as shown in the illustration. HINT: The waveform varies with the blower speed. Text in Illustration Component with harness connected (Solar Ventilation ECU) REPLACE BLOWER MOTOR PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE REPLACE BLOWER MOTOR 2010 Toyota Prius Repair Manual...
  • Page 390 10 kΩ or higher Text in Illustration Front view of wire harness connector (to Solar Ventilation ECU) Front view of wire harness connector (to Solar Ventilation Relay) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE SOLAR VENTILATION ECU 2010 Toyota Prius Repair Manual...
  • Page 391 If the Data List items are not displayed, inspect the communication circuit between the solar ventilation ECU and A/C amplifier PROCEDURE READ VALUE USING TECHSTREAM (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). 2010 Toyota Prius Repair Manual...
  • Page 392 (OFF/ON display does not change for Solar Ventilation Switch Status even though the solar ventilation switch is operated.) REPLACE SOLAR VENTILATION ECU CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION ECU - A/C AMPLIFIER) INSPECT SOLAR VENTILATION SWITCH PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE 2010 Toyota Prius Repair Manual...
  • Page 393 Component without harness connected (Solar Ventilation Switch) REPLACE SOLAR VENTILATION SWITCH CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION SWITCH - BODY GROUND) (a) Measure the resistance according to the value(s) in the table below. Standard Resistance: 2010 Toyota Prius Repair Manual...
  • Page 394 (b) Measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition L22-13 (PVSW) - L66-9 (SW+) Always Below 1 Ω L22-13 (PVSW) - Body ground Always 10 kΩ or higher Text in Illustration 2010 Toyota Prius Repair Manual...
  • Page 395 Tester Connection Condition Specified Condition L17-25 (PVSW) - L22-14 (PVSO) Always Below 1 Ω L17-25 (PVSW) - Body ground Always 10 kΩ or higher Text in Illustration Front view of wire harness connector (to A/C Amplifier) 2010 Toyota Prius Repair Manual...
  • Page 396 REPLACE SOLAR VENTILATION ECU (a) Replace the solar ventilation ECU with a known good one and check if the same problem occurs again Same problem does not occur. REPLACE A/C AMPLIFIER END (SOLAR VENTILATION ECU WAS DEFECTIVE) 2010 Toyota Prius Repair Manual...
  • Page 397 The moon roof glass assembly (solar panel) is not in the shade Moon roof glass assembly (solar panel) status No fallen leaves or dirt is present on the moon roof glass assembly (solar 2010 Toyota Prius Repair Manual...
  • Page 398 Front view of wire harness connector (to Solar Ventilation ECU) CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION ECU - SOLAR PANEL, BODY GROUND) READ VALUE USING TECHSTREAM (a) Reconnect the solar ventilation ECU connector. (b) Connect the Techstream to the DLC3. 2010 Toyota Prius Repair Manual...
  • Page 399 A/C amplifier REPLACE SOLAR VENTILATION ECU PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION ECU - SOLAR PANEL, BODY GROUND) (a) Disconnect the solar ventilation ECU connector. 2010 Toyota Prius Repair Manual...
  • Page 400 Front view of wire harness connector (to Solar Ventilation ECU) Front view of wire harness connector (to Moon Roof Glass Assembly (Solar Panel)) REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE MOON ROOF GLASS ASSEMBLY (SOLAR PANEL) 2010 Toyota Prius Repair Manual...
  • Page 401 When this circuit malfunctions, Data List items for the solar ventilation system will not be displayed. WIRING DIAGRAM INSPECTION PROCEDURE PROCEDURE CHECK HARNESS AND CONNECTOR (SOLAR VENTILATION ECU - A/C AMPLIFIER) (a) Disconnect the solar ventilation ECU connector. 2010 Toyota Prius Repair Manual...
  • Page 402 REPAIR OR REPLACE HARNESS OR CONNECTOR REPLACE SOLAR VENTILATION ECU (a) Replace the solar ventilation ECU with a known good one and check if the same problem occurs again Same problem does not occur. REPLACE A/C AMPLIFIER 2010 Toyota Prius Repair Manual...
  • Page 403 END (SOLAR VENTILATION ECU WAS DEFECTIVE) 2010 Toyota Prius Repair Manual...