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Table of Contents
Related Manuals for Toyota Prius ZVW41 Series
Summary of Contents for Toyota Prius ZVW41 Series
- Page 1 Gasoline-Electric Hybrid Synergy Drive ZVW41 Series...
- Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius V gasoline-electric hybrid vehicles. 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 V hybrid, as they may not be familiar to dismantlers.
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Page 3: Table Of Contents
Table of Contents About the Prius V ............................1 Prius V Identification ..........................2 Exterior .................................3 Prius V Identification (Continued)......................4 Interior................................4 Engine Compartment ............................5 Hybrid Component Locations & Descriptions..................6 Specifications ..............................7 Hybrid Synergy Drive Operation......................8 Vehicle Operation............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery..............9 HV Battery Pack............................9 Components Powered by the HV Battery Pack.....................9 HV Battery Pack Recycling .........................10... -
Page 5: About The Prius V
The Prius V wagon joins the PRIUS, CAMRY hybrid and HIGHLANDER 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 6: Prius V Identification
Prius V Identification In appearance, the 2012 model year 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. -
Page 7: Exterior
Prius V Identification (Continued) Exterior logos on the back door. logo on each front fender. Exterior Left Side View Exterior Front View Exterior Rear View Exterior Rear and Left Side View... -
Page 8: Prius V Identification (Continued)
Prius V Identification (Continued) Interior Instrument cluster (speedometer, READY light, shift state 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. -
Page 9: Engine Compartment
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... -
Page 10: Hybrid Component Locations & Descriptions
Hybrid Component Locations & Descriptions Component Location Description 12 Volt Right Side of A lead-acid battery that supplies power to the low voltage Auxiliary Battery Cargo Area devices. Hybrid Vehicle Cargo Area, 201.6 Volt Nickel Metal Hydride (NiMH) battery pack (HV) Battery Pack Mounted to Cross consisting of 28 low voltage (7.2 Volt) modules connected... -
Page 11: 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), Permanent Magnet Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 201.6 Volt Sealed NiMH Battery Curb Weight: 3,295 lbs/1,495 kg Fuel Tank: 11.9 gals/45.0 liters Frame Material: Steel Unibody... -
Page 12: 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 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The Prius V features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. 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 14: Hv Battery Pack Recycling
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (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 26) or the nearest Toyota dealer. Auxiliary Battery •... -
Page 15: High Voltage Safety
High Voltage Safety 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 201.6 to 650 Volts DC. -
Page 16: 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 Volts Volts DC Hybrid Vehicle Computer Auxiliary Battery Compressor Electric Inverter/ Generator Converter Electric Volts DC Motor HV Battery Pack 3-Phase High Voltage Safety System –... -
Page 17: 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 18: Spills
Spills The Prius V contains the same common automotive fluids used in other non-hybrid Toyota vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked. -
Page 19: Dismantling The Vehicle
Dismantling the vehicle The following 2 pages contain general instructions for use when working on a Prius V. Read these instructions before proceeding to the HV battery removal instructions on page 18. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. - 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.
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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 Disconnect the cable from the auxiliary battery negative (-) terminal. Disconnect the cable from the auxiliary battery positive (+) terminal. (6) Remove the 12volt auxiliary battery. 4. REMOVE SERVICE PLUG GRIP HV battery Caution: Wear insulated gloves for the following 3 steps.
- 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 separate the 2 guides to remove the front inner track bracket cover. Lift up the seat track adjusting handle and move the seat to the foremost position. Disengage the 4 claws and remove the rear inner seat track bracket cover.
- Page 26 Lift up the seat track adjusting handle and move the seat to the rearmost position. Remove the 2 bolts on the front side of the seat. (10) Remove the rear seat assembly RH. 9. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT Using a clip remover, remove the clip.
- Page 27 (2) Disconnect the battery cooling blower assembly connector and 2 clamps. (3) Remove the 2 bolts, nut and battery cooling blower assembly. 12. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY Caution: Wear insulated gloves for the following 2 steps. Using the service plug grip, remove the battery cover lock striker.
- Page 28 13. REMOVE FRAME WIRE Caution: Wear insulated gloves. Notice: Insulate the terminals of the removed frame wire with insulating tape. Remove the 2 nuts, then disconnect the frame wire from the hybrid battery junction block assembly. Disconnect the clamp and frame wire. 14.
- Page 29 Remove the 6 bolts shown in the illustration. (3) Remove the HV battery. 16. The HV battery pack is recyclable. Contact your Toyota distributor (if included on the HV battery caution label) or contact the nearest Toyota dealer (see the next 2 pages for samples of the HV battery caution label).
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Page 30: Hv Battery Caution Label
HV Battery Caution Label 1. For U.S.A. 2. Fo CANADA...