Toyota Prius ZVW35 Series Dismantling Manual
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Toyota Prius ZVW35 Series Dismantling Manual

Gasoline-electric hybrid synergy vehicle
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Summary of Contents for Toyota Prius ZVW35 Series

  • Page 1 Plug-in Hybrid Gasoline-Electric Hybrid Synergy Drive ZVW35 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius Plug-in gasoline-electric hybrid vehicles. Prius Plug-in hybrid dismantling procedures are similar to other non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota Prius Plug-in hybrid, as they may not be familiar to dismantlers.
  • Page 3 Exterior Rear and Left Side View 2010 Model 2012 Model Exterior Front and Left Side View © 2011 Toyota Motor Corporation All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation.

  • Page 4: Table Of Contents

    Table of Contents About the Prius Plug-in hybrid (2010 Model)....................1 Prius Plug-in hybrid Identification (2010 Model)..................2 Exterior .................................3 Interior................................4 Engine Compartment ............................5 Hybrid Component Locations & Descriptions (2010 Model) ..............6 Specifications ..............................7 Hybrid Synergy Drive Operation (2010 Model) ..................8 Vehicle Operation............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model) ..........9 HV Battery Pack............................9 Components Powered by the HV Battery Pack.....................9...
  • Page 5 High Voltage Safety (2012 Model) ......................46 High Voltage Safety System........................46 Service Plug Grip ............................47 Precaution to be observed when dismantling the vehicle (2012 Model)..........48 Necessary Items ............................48 Spills (2012 Model) .............................49 Dismantling the vehicle (2012 Model).......................50 Removal of HV battery (2012 Model) .......................55 HV Battery Caution Label (2012 Model) ....................69...

  • Page 6: About The Prius Plug-In Hybrid (2010 Model)

    The Prius Plug-in hybrid contains a gasoline engine, an electric motor, and a newly developed large capacity Li-ion battery. It is the first Toyota hybrid that allows the HV battery to be plugged-in and charged by an external power source. Two power sources are stored on board the vehicle: 1.

  • Page 7: Prius Plug-In Hybrid Identification (2010 Model)

    Prius Plug-in hybrid Identification (2010 Model) In appearance, the 2010 model year Prius Plug-in hybrid is a 5-door hatchback. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl and on the left side door pillar.

  • Page 8: Exterior

    Prius Plug-in hybrid Identification (2010 Model - Continued) Exterior logo on the front right fender. Charge inlet door with logo, located on left side front fender. Plug-in Hybrid decals located on the sides of the vehicle. Exterior Left Side View Exterior Front and Rear View Exterior Rear and Left Side View...

  • Page 9: Interior

    Prius Plug-in hybrid Identification (2010 Model - Continued) Interior Instrument cluster (speedometer, READY light, shift position indicators, warning lights) located in center of the dash and near the base of the windshield. Hint: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated. Interior View Instrument Cluster View...

  • Page 10: Engine Compartment

    Prius Plug-in hybrid Identification (2010 Model - Continued) Engine Compartment 1.8-liter aluminum alloy gasoline engine. Logo on the plastic engine cover. Orange colored high voltage power cables. Engine Compartment View Power Cables...

  • Page 11: Hybrid Component Locations & Descriptions (2010 Model)

    Hybrid Component Locations & Descriptions (2010 Model) Component Location Description 12 Volt Auxiliary Right Side of A lead-acid battery that supplies power to the low voltage Battery Cargo Area devices. Hybrid Vehicle (HV) Cargo Area 346 Volt Lithium-ion (Li-ion) battery pack consisting of Battery Assembly 3.6 Volt cells connected in a series-parallel circuit.

  • Page 12: Specifications

    Hybrid Component Locations & Descriptions (2010 Model - Continued) Specifications Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine Electric Motors 80 hp (60 kW), Permanent Magnet Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 346 Volt Sealed Li-ion Battery Curb Weight: 3,362 lbs/1,525 kg Fuel Tank: 11.9 gals/45.0 liters Frame Material: Steel Unibody...

  • Page 13: Hybrid Synergy Drive Operation (2010 Model)

    Hybrid Synergy Drive Operation (2010 Model) Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster.

  • Page 14: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery (2010 Model)

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model) The Prius Plug-in hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Lithium-ion (Li-ion) battery cells. HV Battery Pack • The HV battery pack is enclosed in a metal case and is rigidly mounted to the cargo area floor pan cross member behind the rear seat.

  • Page 15: Hv Battery Pack Recycling

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model - Continued) HV Battery Pack Recycling • The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV battery Caution Label (see page 35) or the nearest Toyota dealer. Auxiliary Battery •...

  • Page 16: High Voltage Safety (2010 Model)

    High Voltage Safety (2010 Model) The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the battery pack, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 346 to 650 Volts DC.

  • Page 17: Service Plug Grip

    High Voltage Safety (2010 Model - Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 16). 12 Volts Volts DC Hybrid Vehicle Computer Auxiliary Battery Compressor Electric Inverter/ Generator Converter Electric Volts DC Motor HV Battery Pack...

  • Page 18: Precaution To Be Observed When Dismantling The Vehicle (2010 Model)

    Precaution to be observed when dismantling the vehicle (2010 Model) WARNING: The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component.

  • Page 19: Spills (2010 Model)

    Spills (2010 Model) The Prius Plug-in hybrid contains the same common automotive fluids used in other non-hybrid Toyota vehicles, with the exception of the Li-ion electrolyte used in the HV battery assembly. The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the battery cell separators, even if the battery cells are crushed or cracked, it is unlikely that liquid electrolyte will leak.

  • Page 20: Dismantling The Vehicle (2010 Model)

    Dismantling the vehicle (2010 Model) The following 2 pages contain general instructions for use when working on a Prius Plug-in hybrid. Read these instructions before proceeding to the HV battery removal instructions on page 19. WARNING: The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 21 3. Remove the 3 service plug grips. Caution: Wear insulated gloves for the following 3 steps. (1) Slide the handle of the service plug grip to the left. (2) Raise the release handle of the service plug grip (3) Remove the service plug grip. (4) Apply insulating tape to the socket of the service plug grip to insulate it.
  • Page 22 Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 9. With the exception of the HV battery, remove parts by following procedures which are similar to conventional Toyota vehicles. For the removal of the HV battery, refer to the following pages.

  • Page 24: Removal Of Hv Battery (2010 Model)

    Removal of HV battery (2010 Model) WARNING: Be sure to wear insulated gloves when handling high-voltage parts. Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work. Power remains in the high voltage electrical system for 10 minutes even after the HV battery pack is shut off because the circuit has a condenser that stores power.
  • Page 25 4. Remove the rear No. 4 floor board. (1) Using a clip remover, disengage the 3 clips and remove the rear No. 4 floor board. 5. Remove the rear No. 1 floor board. (1) Using a clip remover, disengage the 8 clips. (2) Disangage the 3 fasteners and disconnect the rear No.
  • Page 26 6. Remove the rear deck trim cover. (1) Remove the bolt. (2) Using a clip remover, disengage the 4 clips. (3) Disengage the 4 claws and 4 guides, and remove the rear deck trim cover. 7. Remove the hybrid battery carrier bracket. (1) Remove the bolt.
  • Page 27 8. Remove the 3 service plug grips. Caution: • Wear insulated gloves. • Before inspecting or servicing the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, be sure to follow all safety measures, such as wearing insulated gloves and removing the 3 service plug grips to prevent electrocution.
  • Page 28 9. Remove the 9 bolts and inverter terminal cover. Caution: Wear insulated gloves. 10. Check the voltage at the terminals in the inspection point in the power control unit. Caution: Wear insulated gloves. To prevent serious injury or death, do not proceed with dismantling of the HV system until the voltage at the terminals in the inspection point is 0 V.
  • Page 29 13. Remove the rear side seatback assembly RH. (4) Remove the bolt. (5) Disengage the 2 guides and remove the rear side seatback assembly RH. 14. Remove the rear side seatback assembly LH. (1) Remove the bolt.
  • Page 30 (2) Disengage the 2 guides and remove the rear side seatback assembly LH. 15. Disconnect the rear center seat belt assembly. Remove the bolt and disconnect the anchor part of the rear center seat belt assembly. 16. Remove the rear seatback assembly LH. (1) Remove the 2 bolts and rear seatback assembly 17.
  • Page 31 18. Remove the battery cooling blower bracket. Notice: • Be sure not to touch the fan part of the battery cooling blower assemblies. • Do not lift the battery cooling blower assemblies using the wire harness. Disconnect the battery cooling blower assembly connectors.
  • Page 32 Remove the 2 clips and No. 5 hybrid battery intake duct (main). 20. Remove the battery cooling blower assembly. Notice: • Be sure not to touch the fan part of the battery cooling blower assemblies. • Do not lift the battery cooling blower assemblies using the wire harness. (1) Remove the 9 nuts and 3 battery cooling blower assemblies.
  • Page 33 22. Remove converter cooling blower bracket. Remove the 2 bolts and converter cooling blower bracket. 23. Remove the No. 2 converter cooling exhaust duct. Remove the 4 clips and No. 2 converter cooling exhaust duct. 24. Remove the No. 3 converter cooling exhaust duct.
  • Page 34 26. Remove the child restraint seat anchor bracket assembly RH. Remove the 2 bolts and child restraint seat anchor bracket sub-assembly RH. 27. Remove the No. 1 hybrid battery intake duct. Remove the clip and No. 1 hybrid battery intake duct (main).
  • Page 35 29. Remove the HV battery cover sub-assembly. Caution: Be sure to wear insulated gloves and protective goggles. Separate the 2 claws and 3 clamps, and remove the indoor electrical key oscillator. Remove the 18 nuts and HV battery cover Front sub-assembly.
  • Page 36 31. Remove the hybrid vehicle converter. Caution: Be sure to wear insulated gloves and protective goggles. Notice: Insulate the terminals of the removed frame wire with insulating tape. Disengage the clamp and disconnect the connector. (2) Disconnect the 2 connectors. (3) Remove the 4 nuts and hybrid vehicle converter.
  • Page 37 33. Install HV battery cover sub-assembly. Front Caution: Be sure to wear insulated gloves and protective goggles. Temporarily install the HV battery cover sub-assembly with the 18 nuts to prevent any foreign objects or water from entering the HV battery. 34.
  • Page 38 Disconnect the 4 connectors and 2 clamps. Install the 4 eyebolts in the locations shown in the illustration. Front Hint: Make sure to use the eyebolts supplied with the HV battery. Set the hooks and straps as shown in the illustration.
  • Page 39 Remove the 6 bolts and 2 nuts. Hint: • Attach tape to the feet and edges of the battery to protect tools and the vehicle body. • Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

  • Page 40: Hv Battery Caution Label (2010 Model)

    HV Battery Caution Label (2010 Model) For U.S.A. For CANADA For Europe...

  • Page 41: About The Prius Plug-In Hybrid (2012 Model)

    The Prius Plug-in hybrid contains a gasoline engine, an electric motor, and a newly developed large capacity Li-ion battery. It is the first Toyota hybrid that allows the HV battery to be plugged-in and charged by an external power source. Two power sources are stored on board the vehicle: 3.

  • Page 42: Prius Plug-In Hybrid Identification (2012 Model)

    Prius Plug-in hybrid Identification (2012 Model) In appearance, the 2012 model year Prius Plug-in hybrid is a 5-door hatchback. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl and on the driver door pillar.

  • Page 43: Exterior

    Prius Plug-in hybrid Identification (2012 Model - Continued) Exterior logos on the hatch. logo on the each front fender. Charge inlet door located on right side rear quarter panel. Exterior Left Side View Exterior Front and Rear View Exterior Rear and Right Side View...

  • Page 44: Interior

    Prius Plug-in hybrid Identification (2012 Model - Continued) Interior An instrument cluster (speedometer, READY light, shift position indicators, warning lights) located in center of the dash and near the base of the windshield. logo located on the passenger side of the dash. Hint: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.

  • Page 45: Engine Compartment

    Prius Plug-in hybrid Identification (2012 Model - Continued) Engine Compartment 1.8-liter aluminum alloy gasoline engine. Logo on the plastic engine cover. Orange colored high voltage power cables. Engine Compartment View Power Cables...

  • Page 46: Hybrid Component Locations & Descriptions (2012 Model)

    Hybrid Component Locations & Descriptions (2012 Model) Component Location Description 12 Volt Auxiliary Right Side of A lead-acid battery that supplies power to the Battery Cargo Area low voltage devices. Hybrid Vehicle Cargo Area 207.2 Volt Lithium-ion (Li-ion) battery pack (HV) Battery consisting of 3.7 Volt cells connected in a series Assembly...

  • Page 47: Specifications

    Hybrid Component Locations & Descriptions (2012 Model - Continued) Specifications Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine Electric Motors 80 hp (60 kW), Permanent Magnet Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 207.2 Volt Sealed Li-ion Battery Curb Weight: 3,186 lbs/1,445 kg Fuel Tank: 11.9 gals/45.0 liters 10.6 gals/40.0 liters...

  • Page 48: Hybrid Synergy Drive Operation (2012 Model)

    Hybrid Synergy Drive Operation (2012 Model) Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster.

  • Page 49: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery (2012 Model)

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2012 Model) The Prius Plug-in hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Lithium-ion (Li-ion) battery cells. HV Battery Pack • The HV battery pack is enclosed in a metal case and is rigidly mounted to the cargo area floor pan cross member behind the rear seat.

  • Page 50: Hv Battery Pack Recycling

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2012 Model - Continued) HV Battery Pack Recycling • The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV battery Caution Label (see page 35) or the nearest Toyota dealer. Auxiliary Battery •...

  • Page 51: High Voltage Safety (2012 Model)

    High Voltage Safety (2012 Model) The HV battery assembly powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the HV battery assembly, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 207.2 to 650 Volts DC.

  • Page 52: Service Plug Grip

    High Voltage Safety (2012 Model - Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 16). 12 Volt Auxiliary Hybrid Vehicle Computer Battery Volt DC Volt DC Volt AC Volt DC Compressor Electric Inverter/...

  • Page 53: Precaution To Be Observed When Dismantling The Vehicle (2012 Model)

    Precaution to be observed when dismantling the vehicle (2012 Model) WARNING: The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component.

  • Page 54: Spills (2012 Model)

    Spills (2012 Model) The Prius Plug-in hybrid contains the same common automotive fluids used in other non-hybrid Toyota vehicles, with the exception of the Li-ion electrolyte used in the HV battery assembly. The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the battery cell separators, even if the battery cells are crushed or cracked, it is unlikely that liquid electrolyte will leak.

  • Page 55: Dismantling The Vehicle (2012 Model)

    Dismantling the vehicle (2012 Model) The following 2 pages contain general instructions for use when working on a Prius Plug-in hybrid. Read these instructions before proceeding to the HV battery removal instructions on page 19. WARNING: The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 56 3. Remove the service plug grip. Caution: Wear insulated gloves for the following 5 steps. (1) Remove service hole cover. (2) Slide the handle of the service plug grip to the left. (3) Raise the release handle of the service plug grip.
  • Page 57 4. Carry the removed service plug grip in your pocket to prevent other staff from accidentally reinstalling it while you are dismantling the vehicle. 5. Make other staff aware that a high-voltage system is being dismantled by using the following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 18). 6.
  • Page 58 Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 10. With the exception of the HV battery, remove parts by following procedures which are similar to conventional Toyota vehicles. For the removal of the HV battery, refer to the following pages.
  • Page 59 54 54...

  • Page 60: Removal Of Hv Battery (2012 Model)

    Removal of HV battery (2012 Model) WARNING: Be sure to wear insulated gloves when handling high-voltage parts. Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work. Power remains in the high voltage electrical system for 10 minutes even after the HV battery pack is shut off because the circuit has a condenser that stores power.
  • Page 61 4. Remove the service plug grip. Caution: • Wear insulated gloves. • Before inspecting or servicing the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, be sure to follow all safety measures, such as wearing insulated gloves and removing the 3 service plug grips to prevent electrocution.
  • Page 62 5. Remove the 9 bolts and inverter terminal cover. 6. Check the voltage at the terminals in the inspection point in the power control unit. Caution: Wear insulated gloves. To prevent serious injury or death, do not proceed with dismantling of the HV system until the voltage at the terminals in the inspection point is 0 V.
  • Page 63 11. Remove the rear No. 1 floor board sub-assembly. (1) Disengage the claw and 3 clips, and remove the rear No. 1 floor board sub-assembly. 12. Remove the rear No. 1 floor board. (1) Fold the rear seatback assembly LH forward. (2) Disengage the fastener.
  • Page 64 Using a clip remover, remove the clip. (6) Disengage the 3 fasteners and remove the rear No. 1 floor board. 13. Remove the deck trim service hole cover. (1) Disengage the 4 claws. (2) Disengage the 4 guides and remove the deck trim service hole cover.
  • Page 65 16. Remove the rear door opening trim weatherstrip LH and RH. (1) Remove the rear door opening trim weatherstrip LH and RH. 17. Remove the rear seat cushion assembly. (1) Disengage the front hook of the rear seat cushion assembly from the vehicle body as shown in the illustration.
  • Page 66 (7) Disengage the 2 guides and remove the rear side seatback assembly RH. 16. Remove the rear side seatback assembly LH. (3) Remove the bolt. (4) Disengage the 2 guides and remove the rear side seatback assembly LH.
  • Page 67 17. Remove the luggage hold belt striker (for LH and RH). Remove the 4 bolts. (2) Disengage each guide and remove the 2 luggage hold belt striker assemblies. 18. Remove the tonneau cover holder cap (for LH and RH). (1) Using a screwdriver, disengage the claw and remove the tonneau cover holder cap.
  • Page 68 20. Remove deck trim side panel assembly RH. (1) Remove the screw. (2) Disengage the 7 claws and 2 clips and remove the deck trim side panel assembly RH. 21. Remove the battery cooling blower assembly. Notice: • Be sure not to touch the fan part of the battery cooling blower assemblies. •...
  • Page 69 22. Remove the hybrid battery hose assembly. (1) Disconnect the clip. (2) Disengage the claw. (3) Disconnect the grommet and remove the hybrid battery hose assembly. 23. Remove No. 4 hybrid vehicle battery carrier bracket. (1) Remove the bolt and No. 4 hybrid vehicle battery carrier bracket.
  • Page 70 25. Remove No. 1 hybrid vehicle battery shield panel. Caution: Be sure to wear insulated gloves and protective goggles. (1) Disengage the 2 claws and remove the 3 clamps and electrical key oscillator. (2) Disconnect the connector and clamp. (3) Remove the 7 nuts and No. 1 hybrid vehicle battery shield panel.
  • Page 71 29. Remove the No. 2 hybrid battery intake duct (1) Remove the clip and No. 1 hybrid battery intake duct. 30. Remove the HV battery. Caution: Be sure to wear insulated gloves and protective goggles. Notice: Insulate the terminals of the removed frame wire with insulating tape. Remove the 2 bolts from each back door damper stay bracket UPR.
  • Page 72 Disconnect the clamp. Disconnect the connector and 2 clamps. Remove the 2 bolts. Install the 2 engine hangers (12281-28010) with the 2 bolts as shown in the illustration.
  • Page 73 Remove the 8 bolts and 2 nuts. Set the hooks and straps as shown in the illustration. (9) Using a suitable adaptor such as straps, remove the HV battery. Caution: To prevent any accidents and injuries due to Hook the weight of the HV battery, follow all specified procedures and be careful to balance the HV battery when removing or installing it.

  • Page 74: Hv Battery Caution Label (2012 Model)

    HV Battery Caution Label (2012 Model) For U.S.A. For CANADA...

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