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Summary of Contents for Toyota Prius NHW20 Series
- Page 1 Gasoline-Electric Hybrid Synergy Drive NHW20 Series...
- Page 2 It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota Prius as they may not be familiar to dismantlers. High voltage electricity powers an electric motor, generator, electric inverter compressor (for air conditioner) and inverter. All other conventional automotive electrical devices such as the headlights, radio, and gauges are powered from a separate 12-Volt battery.
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Page 3: Table Of Contents
Table of Contents ABOUT THE PRIUS........................1 PRIUS IDENTIFICATION ......................2 Exterior ................................3 Interior................................4 Engine Compartment ............................5 HYBRID COMPONENT LOCATIONS & DESCRIPTIONS ............6 Specifications..............................6 GASOLINE-ELECTRIC HYBRID VEHICLE 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
About the Prius The Toyota Prius (NHW20 Series) is a gasoline-electric hybrid vehicle sold in the world since September 2003. Gasoline-electric hybrid means the vehicle contains a gasoline engine and an electric motor for power. Two energy sources are stored on-board the vehicle: 1. -
Page 6: Prius Identification
Prius Identification In appearance, the Prius is similar to a 5 door hatch back. Exterior, interior, and engine compartment illustrations are provided to assist in the identification. The alphanumeric 17 character, Vehicle Identification Number (VIN), is provided in the front windshield cowl and driver door post. JTDKB22U840020208 Example VIN: (A Prius is identified by the first 6 alphanumeric characters JTDKB2) -
Page 7: Exterior
Exterior Hybrid Synergy Drive PRIUS & logos on trunk. Gasoline fuel filler door located on left side quarter panel. Toyota logo on the hood. Hybrid Synergy Drive Exterior Rear & Left Side View Exterior Left Side View Exterior Front View... -
Page 8: Interior
Prius Identification (Continued) Interior Center cluster mounted automatic transmission shift selector lever. Instrument cluster (speedometer, fuel gauge and warning lights) located in the dash and near the base of the windshield. LCD monitor (fuel consumption and radio controls) located below the instrument cluster. -
Page 9: Engine Compartment
Engine Compartment 1.5 liter aluminum alloy gasoline engine. Toyota Synergy Drive High voltage inverter with the logo on the cover. Orange colored high voltage power cables. Toyota Synergy Drive Logo on Inverter Engine Compartment... -
Page 10: Hybrid Component Locations & Descriptions
Hybrid Component Locations & Descriptions Component Location Description 12-Volt Auxiliary Luggage, RH Side Low voltage lead-acid battery that controls all Battery electrical equipment except electric motor generator and inverter. Hybrid Vehicle Luggage, Mounted 201.6-Volts Nickel Metal Hydride (NiMH) battery pack (HV) Battery to Cross Member &... - Page 11 12-Volt ⊕ Cable Power Cables 12-Volt ⊕ Cable Power Cable...
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Page 12: Gasoline-Electric Hybrid Vehicle Operation
Gasoline-Electric Hybrid Vehicle Operation The vehicle starts and becomes operational by inserting key into key-slot and pressing the ‘ ’ button while depressing brake pedal. However, POWER the gasoline engine does not idle like a typical automobile and will start and stop automatically. -
Page 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The PRIUS contains a high voltage, Hybrid Vehicle (HV) battery pack and a low voltage auxiliary battery. The HV battery pack contains non-spillable, sealed Nickel Metal Hydride (NiMH) battery modules and the auxiliary battery is a typical automotive lead-acid type. -
Page 14: Hv Battery Pack Recycling
HV Battery Pack Recycling • The HV battery pack is recyclable. Contact your Toyota Distributor as mentioned on HV battery Caution Label (see the page 25 to 27) or the nearest Toyota dealer. Auxiliary Battery • The PRIUS also contains a lead-acid 12-Volt battery. This 12-Volt auxiliary battery powers the vehicle electrical systems similarly to a conventional vehicle. -
Page 15: High Voltage Safety
High Voltage Safety The HV battery pack powers the high voltage electrical system with direct current (DC) electricity. A positive and negative power cables are routed from the battery pack, under the vehicle floor pan, to the inverter. Occupants in the vehicle are separated from high voltage electricity by the following systems: High Voltage Safety System •... - Page 16 High Voltage Safety System – Vehicle Shut Off (READY off) High Voltage Safety System – Vehicle On and Operational (READY...
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Page 17: Precaution To Be Observed When Dismantling The Vehicle
Precaution to be observed when dismantling the vehicle WARNING: ・ Never assume that the Prius is shut off simply because it is silent. ・ Assure that READY indicator is off. ・ Remove the key from the key slot. ・ After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals. -
Page 18: Spillage
Spillage The Prius contains the same common automotive fluids used in other Toyota vehicles, with the exception of NiMH electrolyte used in HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that causes damage 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 A Vehicle
Dismantling a vehicle WARNING: ・ Never assume that the Prius is shut off simply because it is silent. ・ Assure that READY indicator is off. ・ Remove the key from the key slot. ・ After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals. - Page 20 Do not rub your eyes but wash them with a dilute boric acid solution or a large amount of water and seek medical care. Remove the parts by the procedures which are similar to the Toyota vehicles with exception of HV battery. As for the removal of HV battery, place refer to...
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Page 22: Removal Of Hv Battery
Removal of HV battery HV battery removal WARNING: ・ Never assume that the Prius is shut off simply because it is silent. ・ Assure that READY indicator is off. ・ Remove the key from the key slot. ・ After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals. - Page 23 3 Remove rear floor board No. 3. Remove the rear floor board No. 3 as shown in the illustration. 4 Disconnect battery negative terminal. Disconnect the negative terminal of the 12 V auxiliary battery. 5 Remove the key from the key slot. Then disconnect the negative (-) terminal of the auxiliary battery and remove the service plug.
- Page 24 7 Remove tonneau cover 8 Remove rear seat cushion Undo the 2 joints shown in the illustration, then remove the rear seat cushion. Joint 9 Remove rear floor board No. 1. Remove the 2 bolts and luggage hold belt strikers. Remove the 5 clips shown in the illustration and the rear floor board No.
- Page 25 11 Remove deck floor box LH. Remove the clip and deck floor box LH. Clip 12 Remove deck trim side panel LH Remove the bolt and luggage hold belt striker Remove the 2 bolts from the deck trim side panel Remove the clip from the deck trim side panel LH.
- Page 26 14 Remove battery carrier bracket Remove the 7 bolts and battery carrier bracket. 15 Remove quarter vent duct inner No. 2. Disconnect the clamp and Battery Blower Relay No. 1 battery blower relay No. 1. Remove the 2 clips. Slide the ventilation inner duct No.
- Page 27 18 Remove battery carrier panel No. 6. Remove the 3 bolts, 2 nuts and battery carrier panel No. 6. 19 Remove junction terminal. 20 Remove frame wire. Remove the 2 nuts, then disconnect the frame wire from the system main relay No.
- Page 28 Disconnect the battery room ventilation hose from Ventilation Hose the floor panel. Remove the HV battery. HV battery pack is recyclable. Contact your Toyota Distributor as mentioned on HV Battery Caution Label or the nearest Toyota Dealer (see the next page).
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Page 29: Hv Battery Caution Label
HV Battery Caution Label 1. for U.S.A. - Page 30 2. for CANADA...
- Page 31 3. For EUROPE and others...
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