Toyota PRIUS+ User Manual
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Toyota PRIUS+ User Manual

Gasoline-electric hybrid synergy drive
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Gasoline-Electric
Hybrid Synergy Drive
ZVW4# Series

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Summary of Contents for Toyota PRIUS+

  • Page 1 Gasoline-Electric Hybrid Synergy Drive ZVW4# Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota PRIUS +/PRIUS v gasoline-electric hybrid vehicles. PRIUS +/PRIUS v 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 +/PRIUS v hybrid, as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    Table of Contents About the PRIUS +/PRIUS v ........................1 PRIUS +/PRIUS v Identification ......................2 Exterior ................................. 3 PRIUS +/PRIUS v Identification (Continued) ..................4 Interior ................................4 Engine Compartment ............................ 5 Hybrid Component Locations & Descriptions ..................6 Specifications ..............................

  • Page 4: About The Prius +/Prius V

    The PRIUS +/PRIUS v wagon joins the PRIUS, CAMRY hybrid and AURIS hybrid as a hybrid model for Toyota. Hybrid Synergy Drive means that the vehicle contains a gasoline engine and an electric motor for power. The two hybrid power sources are stored on board the vehicle: Gasoline stored in the fuel tank for the gasoline engine.

  • Page 5: Prius +/Prius V Identification

    PRIUS +/PRIUS v Identification In appearance, the PRIUS +/PRIUS v is a 5-door wagon. 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, right side floor and on the left side B pillar. JTDZS3EU0C3000101 Example VIN: A PRIUS +/PRIUS v is identified by the first 8 alphanumeric characters JTDZS3EU.

  • Page 6: Exterior

    PRIUS +/PRIUS v Identification (Continued) Exterior  Name plate and logos on the back door.  logo on each front fender.  Exterior Left Side View    Exterior Front View and Rear View     Exterior Rear and Left Side View 3/33...

  • Page 7: Prius +/Prius V Identification (Continued)

    PRIUS +/PRIUS v Identification (Continued) Interior  Instrument cluster (READY indicator, shift state indicators) 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.

  • Page 8: Engine Compartment

    PRIUS +/PRIUS v Identification (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 5/33...

  • Page 9: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description 12 Volt  Auxiliary Right Side of Cargo A lead-acid battery that supplies power to the low voltage Battery Area devices. Hybrid  Vehicle Center Console 201.6 Volt Lithium-ion (Li-ion) battery assembly consisting (HV) Battery of 56 low voltage (3.6 Volt) cells connected in series.

  • Page 10: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine Electric Motors 80 hp (60 kW), AC Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 201.6 Volt Sealed Li-ion Battery Curb Weight: 3,450 lbs/1,565 kg Fuel Tank:...

  • Page 11: Hybrid Synergy Drive Operation

    Hybrid Synergy Drive Operation 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 12: Hybrid Vehicle (Hv) Battery Assembly And Auxiliary Battery

    Hybrid Vehicle (HV) Battery Assembly and Auxiliary Battery The PRIUS +/PRIUS v features a high voltage Hybrid Vehicle (HV) battery assembly that contains sealed Lithium-ion (Li-ion) battery cells. HV Battery Assembly • The HV battery assembly is enclosed in a metal case and is rigidly mounted in the center console.

  • Page 13: Hv Battery Assembly Recycling

    HV Battery Assembly Recycling • The HV battery assembly is recyclable. Contact either your Toyota Distributor as mentioned on HV battery Caution Label (see page 28) or the nearest Toyota dealer. Auxiliary Battery • The PRIUS +/PRIUS v also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle.

  • Page 14: High Voltage Safety

    High Voltage Safety 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 battery assembly, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 201.6 to 650 Volts DC.

  • Page 15: Service Plug Grip

    High Voltage Safety (Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 15).  12 Volt Volts DC Hybrid Vehicle Computer Auxiliary Battery  Compressor     Electric Inverter/ Generator Converter Electric...

  • Page 16: Precaution To Be Observed When Dismantling The Vehicle

    Precaution to be observed when dismantling the vehicle 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 17: Spills

    The PRIUS +/PRIUS v 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 18: Dismantling The Vehicle

    Dismantling the vehicle The following 2 pages contain general instructions for use when working on a PRIUS +/PRIUS v. 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 19 3. Remove the service plug grip. Caution: Wear insulated gloves for the following 4 steps. (1) Slide the handle of the service plug grip to the front. (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 20 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. 17/33...
  • Page 21 18/33...

  • Page 22: Removal Of Hv Battery

    Removal of HV battery 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.
  • Page 23 3. REMOVE SERVICE PLUG COVER (1) Remove the console cover. Front (2) Remove the service plug cover. 4. REMOVE SERVICE PLUG GRIP Caution: Wear insulated gloves for the following 4 steps. (1) Slide the handle of the service plug grip to the front. (2) Raise the release handle of the service plug grip (3) Remove the service plug grip.
  • Page 24 6. CHECK TERMINAL VOLTAGE Check voltage at the terminals in 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 25 Disengage the 2 claws and remove the rear outer seat track bracket cover. Remove the 2 bolts on the rear side of the seat. Lift up the seat track adjusting handle and move the seat to the rearmost position. (10) Remove the 2 bolts on the front side of the seat. (11) Lift up the seat track adjusting handle and move the seat to the center position.
  • Page 26 9. REMOVE CENTER FLOOR CARPET COVER Pull the front center floor carpet cover LH in the direction indicated by the arrow to disengage the 4 claws and guide, and remove the center floor carpet cover LH. 10. REMOVE CENTER FLOOR CARPET COVER (1) Pull the front center floor carpet cover RH in the direction indicated by the arrow to disengage the 4 claws and guide, and remove the center floor...
  • Page 27 12. REMOVE FRONT NO. 2 CONSOLE BOX INSERT (1) Remove the front No. 2 console box insert. 13. REMOVE CONSOLE BOX ASSEMBLY Remove the 4 bolts and 6 clips. (2) Disengage the clamp. (3) Pull the console box assembly in the direction indicated by the arrow to disengage the 4 claws and remove the console box assembly.
  • Page 28 Remove the 4 bolts and No. 1 hybrid battery shield sub-assembly. (3) Disconnect the 4 connectors from the battery smart unit. Notice: Insulate the terminals of the removed frame wire with insulating tape. 15. REMOVE FRAME WIRE Caution: Wear insulated gloves for the following 2 steps. Notice: Insulate the terminals of the removed frame wire with insulating tape.
  • Page 29 (2) Install the frame wire as shown in the illustration. 16. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT Remove the 2 clips and No. 1 hybrid battery exhaust duct. 17. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT Remove the 2 clips and No. 4 hybrid battery intake duct.
  • Page 30 19. REMOVE HV BATTERY ASSEMBLY Caution: Wear insulated gloves. Notice: • Insulate the removed connectors and terminals with insulating tape. • Since the HV battery assembly is very heavy, 2 people are needed to remove the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

  • Page 31: Hv Battery Caution Label

    20. HV BATTERY ASSEMBLY RECYCLING The HV battery assembly is recyclable. Contact your Toyota distributor (if included on the HV battery caution label) or contact the nearest Toyota dealer (see below for samples of the HV battery caution label). Caution: After removing the HV battery, do not reinstall the service plug grip to the HV battery.
  • Page 32 Model name G9280-47170 G9280-47190 G9510-47100 Manufacturer Name of Company : TOYOTA MOTOR CORPORATION Address : 1, Toyota-cho, Toyota, Aichi, 471-8571 JAPAN Department : Hybrid Vehicle Battery Unit Development Div. Representative : Kousuke Suzui Telephone number : +81-565-94-3352 Facsimile number : +81-565-94-3319...
  • Page 33 2. Composition / Information on Ingredients The batteries consist of hermetically sealed lithium ion cells that contain a number of chemicals and materials of construction. However, under normal conditions of use there is no risk of exposure. Composition Concentration Common chemical name/General name CAS Number Concentration range Lithium Nickel Oxide...
  • Page 34 5. Measures for electrolyte leakage from the battery - Take up with dry absorbent cloth. - Move the battery away from the ignition source to open area. Protective clothing : Gas mask for organic gases, safety goggle, safety glove suitable for organic solvents. 6.
  • Page 35 8. Toxicology Information There is no data available on the product itself. The information of the internal cell materials is as follows. Lithium Nickel Oxide-LiNiO2 Acute toxicity : No data available. Irritation : Irritating to eyes. Sensitization Skin sensitization : Nickel or Nickel compounds may cause skin sensitization. (DFG, 2007) Cobalt or Cobalt compounds may cause skin sensitization.
  • Page 36 11. Transportation Information - This product is classified as lithium ion batteries UN3480. During the transportation of the battery, it should be subjected to the regulations on the transportation below. - UN (United Nations): Recommendations on the Transportation of Dangerous Goods Model Regulations Sixteenth revised edition - IATA (International Air Transport Organization) : Dangerous Goods Regulations 52nd Edition Effective 1 January 2011...

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