Toyota Prius HSD 2006 User manual

2005 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied., in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Nov. 7, 2005 01-051107-00
FOREWORD
To assist you in your service activities, this manual explains the main characteristics of the 2006 PRIUS, in
particular providing a technical explanation of the construction and operation of new mechanisms and new
technology used.
Applicable models: NHW20 series
This manual is divided into 3 sections.
1. Introduction - Changed features and model line-up are explained.
2. New Features - Technical explanation of the construction and operation of each new system and
component.
3. Appendix - Major technical specifications of the vehicle.
CAUTION, NOTICE, REFERENCE and NOTE are used in the following ways:
CAUTION A potentially hazardous situation which could result in injury if instructions are
ignored.
NOTICE Damage to the vehicle or components may occur if instructions are ignored.
REFERENCE Explains the theory behind mechanisms and techniques.
NOTE Notes or comments not included under the above 3 titles.
For detailed service specifications and repair procedures, refer to the following Repair Manuals:
Manual Name Pub. No.
2006 PRIUS Repair Manual
2006 PRIUS Electrical Wiring Diagram RM01R0U EM01R0U
All information contained herein is the most up-to-date at the time of publication. We reserve the right to make
changes without prior notice.

INTRODUCTION - OUTLINE OF NEW FEATURES
INTRODUCTION
01RMO01Y
: Soft Pad Application Areas
2
OUTLINE OF NEW FEATURES
1. Exterior
The design of the headlights and the radiator grille has been changed.
A new front spoiler has been provided as standard equipment.
The design of the rear combination lights has been changed.
The following exterior colors have been provided.
Color No. Color Name Note
040 Super White II Carryover
1F7 Silver Metallic New
1G3 Gray Metallic New
202 Black Carryover
3R3 Red Mica Metallic New
4S2 Bronze Mica Metallic Carryover
6U0 Light Green Metallic New
8S2 Blue Mica Metallic Carryover
2. Interior
Soft pads are used on the driver side mid panel of the instrument panel, on the front passenger side outer
surface of the upper door and glove box, and on the upper door trims for enhanced feel and quality.

IN
INTRODUCTION - OUTLINE OF NEW FEATURES
01RMO02Y
340 mm (13.4 in.)
3
3. Rear Seat
The surface width of the rear seat has been increased from 290 mm (11.4 in.) to 340 mm (13.4 in.) for
enhanced ride comfort.
The hip point has been lowered 6 mm (0.2 in.) to provide ample head clearance and enhance ergonomics.
4. THS (Toyota Hybrid System) Control System
The DTCs (Diagnostic Trouble Codes) for the following detection item have been changed in accordance
with SAE requirements:
DTC
Detection Item
’06 Model ’05 Model Detection Item
P0AE7/224 P0AA1/224 Hybrid Battery Positive Contactor Circuit Stuck Closed
P0AE6/225 P0AA2/225 Hybrid Battery Positive Contactor Circuit Stuck Open
P0ADC/226 P0AA1/226 Hybrid Battery Positive Contactor Circuit Stuck Closed
P0ADB/227 P0AA2/227 Hybrid Battery Positive Contactor Circuit Stuck Open
P0AE0/228 P0AA4/228 Hybrid Battery Negative Contactor Circuit Stuck Closed
P0ADF/229 P0AA5/229 Hybrid Battery Negative Contactor Circuit Stuck Open
5. Hybrid Battery System
The DTCs for the following detection items have been changed in accordance with SAE requirements:
DTC
Detection Item
’06 Model ’05 Model Detection Item
P0AFA P3030 Disconnection Between Battery and ECU

INTRODUCTION - OUTLINE OF NEW FEATURES
01RMO03Y
255BE29
’06 Model
’05 Model
Shift Position Indicator Light READY Indicator Light
Tire Pressure Warning Light
4
6. 1NZ-FXE Engine
The construction of the EVAP (evaporative emission) control system has been changed. The VSV (for
Canister Closed Valve) used on the ’05 models has been discontinued, and a canister pump module is used
on the ’06 models.
The EVAP service port provided on the ’05 models is removed from the ’06 models.
Along with the change in the construction of the EVAP control system, some DTCs have been added and
changed.
7. Tire Pressure Warning System
A direct-sensing type tire pressure warning system has been newly provided as standard equipment.
8. Body
The reinforcements around the dash panel are optimized to help ensure body rigidity and drivability.
The reinforcements are optimally allocated to the installation portion of the rear shock absorber and around
lower back panel, thus helping ensure body rigidity and drivability.
The damping material is provided on the interior side of the dash panel to dampen vibration of the dash
panel, thus ensuring quietness.
The acoustic film is provided as the inner layer of the laminated glass for the front windshield glass, thus
ensuring quietness.
9. Combination Meter
The size of the indication of the shift position indicator light has been increased from the ’05 model for
enhanced visibility.
The READY indicator light has been relocated from the reflective virtual image display meter to the
indicator area for enhanced visibility.
Along with the use of the tire pressure warning system, a new tire pressure warning light has been provided.

IN
INTRODUCTION - OUTLINE OF NEW FEATURES 5
10. SRS Airbag System
On all models, no-contact type belt buckle switches are used on the right and left front seats, and a front
passenger occupant classification system is used on the front passenger seat.
11. Navigation System with AV System
The navigation system with AV (Audio Visual) system contains an updated navigation system in which new
functions have been added.
The display color is made up from 32,000 colors, realizing the excellent design of the screen.
The navigation voice guidance is available in three languages: English, French and Spanish.
12. TOYOTA Parking Assist System
A rear view monitor system is available as optional equipment on all models.

INTRODUCTION - EXTERIOR APPEARANCE
01RMO04Y
01RMO05Y
6
EXTERIOR APPEARANCE

IN
INTRODUCTION - MODEL CODE & MODEL LINE-UP
NHW20 L - A H E E B A
12345678
1BASIC MODEL CODE
NHW20: With 1NZ-FXE Engine
2STEERING WHEEL POSITION
L: Left-hand Drive
4BODY TYPE
H: 4-door Hatchback
5GEAR SHIFT TYPE
E: Automatic
6GRADE
E: Standard
8DESTINATION
A: U.S.A.
K: Canada
3MODEL NAME
A: Prius 7ENGINE SPECIFICATION
B: Atkinson
7
MODEL CODE
MODEL LINE-UP
DESTINATION
ENGINE
BODY TYPE
GRADE
TRANSAXLE
DESTINATION
ENGINE
BODY
TYPE
GRADE
P112 Automatic
U.S.A.
1NZ FXE
4-door
Standard
NHW20L-AHEEBA
Canada 1NZ-FXE
4 door
Hatchback Standard NHW20L-AHEEBK

8
- MEMO -

NEW FEATURES - EXTERIOR
NEW FEATURES
01RMO07Y01RMO06Y
Turn Signal Light Clearance Light and Side Maker
Condenser Lens
Headlight
’06 Model ’05 Model
01RMO09Y01RMO08Y
Chrome Plating
’06 Model ’05 Model
10
EXTERIOR
HEADLIGHT
A newly designed headlight that is integrated with a clearance light and a turn signal light is used.
A condenser lens that also provides a light distribution function is used below the turn signal light in order
to achieve an innovative look.
A clear smoke paint has been provided on the extension area in order to provide a high quality appearance.
RADIATOR GRILLE
The exterior panel color of the horizontal bars of the radiator grille has been changed to chrome plating in
order to provide a high quality appearance.

NF
NEW FEATURES - EXTERIOR
01RMO11Y01RMO10Y
Front Spoiler
’06 Model ’05 Model
01RMO13Y01RMO12Y
Stop Light
Turn Signal Light
Back-up Light
Plated Molding
Side Marker
Taillight
’06 Model ’05 Model
11
FRONT SPOILER
A new front spoiler, which is made of TSOP (Toyota Super Olefin Polymer) that excels in recyclability, has
been provided under the front bumper for enhanced appearance.
REAR COMBINATION LIGHT
A plated molding is used in the center of the rear combination light to provide a high quality appearance.
The extension of the stop light portion has been changed from black to vapor deposition aluminum in order
to provide a high quality appearance.

NEW FEATURES - 1NZ-FXE ENGINE
12
1NZ-FXE ENGINE
ENGINE CONTROL SYSTEM
1. General
The engine control system of the 1NZ-FXE engine on the ’06 models has following systems.
System Outline ’06
Models ’05 Models
SFI
(Sequential Multiport Fuel
Injection)
An L-type SFI system directly detects the intake air
mass with a hot wire type mass air flow meter.  
ESA
(Electronic Spark Advance)
Ignition timing is determined by the ECM based on
signals from various sensors. The ECM corrects
ignition timing in response to engine knocking.  
ETCS-i
(Electronic Throttle Control
System-intelligent)
The ECM optimally controls the throttle valve opening
in accordance with the engine conditions and the
ETCS-i control request received from the HV ECU.  
VVT-i
Controls the intake camshaft to an optimal valve
timing in accordance with the engine conditions and
the control request received from the HV ECU.  
VVT i
(Variable Valve
Timing-intelligent) The maximum retard closing timing of the intake valve
has been changed from 115to 105ABDC (After
Bottom-Dead-Center). As a result, the cold-starting
performance of the engine has been improved.
 
Coolant Heat Storage
System
The ECM actuates an electric water pump in the
coolant heat storage system to recover the coolant
heated by the engine, store the hot coolant in the
coolant heat storage tank, and supply it to the engine
before starting a cold engine. This optimizes the
combustion performance of the engine during
cold-starting and reduces HC exhaust emissions.
 
Air-fuel Ratio Sensor,
Oxygen Sensor Heater
Control
The temperature of the air fuel ratio sensor or oxygen
sensor is maintained at an appropriate level to increase
accuracy of detection of the oxygen concentration in
the exhaust gas.
 
Fuel Pump Control
Fuel pump operation is controlled by signal from
the ECM.
A fuel cut control is used to stop the fuel pump when
the airbag is deployed during front or side collision.
 
Cooling Fan Control
The ECM steplessly controls the speed of the fans in
accordance with the engine coolant temperature,
vehicle speed, engine speed, and air conditioning
operating conditions. As a result, the cooling
performance has been improved.
 
(Continued)

NF
NEW FEATURES - 1NZ-FXE ENGINE 13
System
Outline
’06 ’05
System Outline
06
Models
05
Models
The ECM controls the purge flow of evaporative
emission (HC) in the canister in accordance with
engine conditions.  
EVAP (Evaporative
Emission) Control System
[See page 16]
Approximately five hours after the power source mode
has been selected to OFF, the ECM operates the leak
detection pump to detect any evaporative emission
leakage occurring in the EVAP (evaporative emission)
control system through changes in the system
pressure.
—
HV Immobilizer Fuel delivery, ignition, and starting of the hybrid
system are prohibited if an attempt is made to start the
hybrid system with an invalid key.  
Dia
g
nosis
When the ECM detects a malfunction, the ECM
diagnoses and memorizes the failed section.  
Diagnosis
[See page 29] All the DTCs (Diagnostic Trouble Codes) have been
made to correspond to the SAE controlled codes.  
Fail-safe When the ECM detects a malfunction, the ECM stops
or controls the engine according to the data already
stored in the memory.  

NEW FEATURES - 1NZ-FXE ENGINE
255EG14
SENSOR
MASS AIR FLOW METER
INTAKE AIR
TEMP. SENSOR
THROTTLE
POSITION SENSOR
KNOCK SENSOR
CRANKSHAFT
POSITION SENSOR
CAMSHAFT POSITION
SENSOR
ENGINE COOLANT
TEMP. SENSOR
COOLANT HEAT
STORAGE TANK
OUTLET TEMP. SENSOR
AMBIENT TEMP. SENSOR
OIL PRESSURE SWITCH
AIR-FUEL RATIO SENSOR
(Bank1, Sensor1)
OXYGEN SENSOR
(Bank1, Sensor1)
FUEL TANK
PRESSURE SENSOR
VG
THA
VTA
VTA2
KNK1
NE
G2
THW
THW2
TAM
MOPS
A1A
OX1B
PTNK
ECM
#10
#20
#30
#40
IGT1 - 4
IGF
OCV
M
FC
HA1A
HA1B
WPL
WSL1
WSL2
WBAD
ACTUATOR
SFI
No. 1 INJECTOR
No. 2 INJECTOR
No. 3 INJECTOR
No. 4 INJECTOR
ESA
IGNITION COIL
with IGNITER
SPARK PLUGS
VVT-i
CAMSHAFT TIMING
OIL CONTROL VALVE
ETCS-i
THROTTLE
CONTROL MOTOR
FUEL PUMP CONTROL
CIRCUIT OPENING RELAY
OXYGEN SENSOR, AIR-FUEL
RATIO SENSOR HEATER CONTROL
Bank 1, Sensor 1
Bank 1, Sensor 2
COOLANT HEAT STORAGE
SYSTEM CONTROL
ELECTRIC WATER PUMP
WATER VALVE
VALVE POSITION SENSOR
14
2. Construction
The configuration of the engine control system in the 1NZ-FXE engine is shown in the following chart.
(Continued)

NF
NEW FEATURES - 1NZ-FXE ENGINE
01REG01Y
ENGINE SWITCH
CANISTER PRESSURE
SENSOR
BATTERY
EFI MAIN RELAY
DLC3
HV ECU
ACCELERATOR
PEDAL POSITION
SENSOR
BODY ECU
AIR CONDITIONING
ECU
IGSW
PPMP
BATT
MREL
+B
TC
WFSE
TACH
CANL
CAN
ECM
GATEWAY
ECU
FAN
EVP1
TBP
MPMP
VPMP
TACH
W
CANH
ACV-LAN
BEAN
COOLING FAN CONTROL
COOLING FAN RELAY
EVAPORATIVE EMISSION
CONTROL
Purge VSV
VSV (for Purge Flow
Switching Valve)
CANISTER PUMP MODULE
LEAK DETECTION PUMP
VENT VALVE
COMBINATION METER
MIL
BATTERY ECU
MULTI DISPLAY
TRANSPONDER
KEY ECU
METER ECU
CERTIFICATION ECU*
15
*: Models with Smart Key System

NEW FEATURES - 1NZ-FXE ENGINE
Service Tip
The canister pump module performs the EVAP leak check. This check is done approximately five
hours after engine is turned off.*
So you may hear sound coming from underneath the luggage compartment for several minutes. It
does not indicate a malfunction.
NOTICE
The pinpoint pressure test procedure is carried out by pressurizing the fresh air line that runs from
the canister pump module to the fuel filler neck.
For details, refer to the 2006 Prius Repair Manual (Pub. No. RM01R0U).
16
3. EVAP (Evaporative Emission) Control System
General
The EVAP (evaporative emission) control system prevents the vapor gas that is created in the fuel tank from
being released directly into the atmosphere.
The canister stores the vapor gas that has been created in the fuel tank.
The ECM controls the purge VSV in accordance with the driving conditions in order to direct the vapor
gas into the engine, where it is burned.
In this system, the ECM checks the evaporative emission leak and outputs DTCs (Diagnostic Trouble
Codes) in the event of a malfunction. An EVAP (evaporative emission) leak check consists of an
application of a vacuum pressure to the system and monitoring the changes in the system pressure in order
to detect a leakage.
This system consists of a purge VSV, VSV (for purge flow switching valve), canister, canister pump
module, fuel tank pressure sensor, and ECM.
The ORVR (Onboard Refueling Vapor Recovery) function is provided.
The canister pressure sensor has been included in the canister pump module.
The canister filter has been provided on the fresh air line. This canister filter is maintenance-free.
The fuel tank pressure sensor detects the pressure in the fuel tank while the engine is running, and sends
the resulting signal to the ECM. Based on this signal, the ECM detects any malfunction in the purge VSV
and the VSV (for purge flow switching valve).
The following are the typical conditions for enabling an EVAP leak check:
Five hours have ela
p
sed after the en
g
ine has been turned OFF.*
Five
hours
have
elapsed
after
the
engine
has
been
turned
OFF
.
Altitude: Below 2400 m (8000 feet)
Typical Enabling
Altitude:
Below
2400
m
(8000
feet)
Battery Voltage: 10.5 V or more
Typical
Enabling
Condition
Battery
Voltage:
10.5
V
or
more
Power Source Mode: OFF
Engine Coolant Temperature: 4.4 to 35C (35 to 95F)
gp ( )
Intake Air Temperature: 4.4 to 35C (35 to 95F)
*: If engine coolant temperature does not drop below 35C (95F), this time should be extended to 7 hours.
Even after that, if the temperature is not less than 35C (95F), the time should be extended to 9.5 hours.
The EVAP service port provided on the ’05 models is removed from the ’06 models.

NF
NEW FEATURES - 1NZ-FXE ENGINE
01REG02Y
255EG12
To Intake Manifold
Purge VSV
ECM Purge Line
VSV (For Purge Flow Switching Valve)
Canister
EVAP Line Recirculation Line
Canister Pump Module Filter
Fuel Tank
Pressure
Sensor
Fresh Air Line
Canister Filter
Leak Detection Pump
Canister Pressure Sensor Bladder Tank Fuel Tank
Purge VSV ECM
EVAP Service Port
VSV
(For Purge Flow Switching Valve)
EVAP Line Purge Line Canister
Fresh Air Line
Filter Vapor Pressure
Sensor
Recirculation Line
VSV (For Canister Close Valve)
Bladder Tank Fuel Tank
’06 Models
’05 Models
Vent
Valve
17
System Diagram

NEW FEATURES - 1NZ-FXE ENGINE
18
Function of Main Components
Component Function
Canister Contains activated charcoal to absorb the vapor gas that
is created in the fuel tank.
Fresh Air Line Fresh air goes into the canister and the cleaned drain air
goes out into the atmosphere.
Cit
Vent Valve Opens and closes the fresh air line in accordance with the
signals from the ECM.
Canister
Pump
Module
Leak Detection
Pump Applies vacuum pressure in the EVAP control system in accordance with the signals from the ECM.
M
o
d
u
l
eCanister
Pressure Sensor Detects the pressure in the EVAP control system and sends the signals to the ECM.
Purge VSV
Opens in accordance with the signals from the ECM when
the system is purging, in order to send the vapor gas that
was absorbed by the canister into the intake manifold.
During the system monitoring mode, this valve controls
the introduction of the vacuum into the fuel tank.
Canister Filter Prevents dust and debris in the fresh air from entering the
system.
VSV (For Purge Flow Switching Valve) Switches the passages from the charcoal canister to the
purge line and from the fuel tank to the purge line.
Fuel Tank Pressure Sensor Detects the pressure in the fuel tank while the engine is
running, and sends the resulting signal to the ECM.
ECM
Controls the canister pump module and the purge VSV in
accordance with the signals from various sensors, in order
to achieve a purge volume that suits the driving
conditions. In addition, the ECM monitors the system for
any leakage and outputs a DTC if a malfunction is found.

NF
NEW FEATURES - 1NZ-FXE ENGINE
228TU119
Fuel Tank Cap Fresh Air
Fuel Inlet Pipe
To Filter
Cleaned Drain Air
19
Construction and Operation
1) Fuel Inlet (Fresh Air Line Inlet)
The flesh air from the atmosphere and drain air cleaned by the canister will go in and out to the system
through the passage shown below.

NEW FEATURES - 1NZ-FXE ENGINE
D13N16
Fresh Air
Pump Motor
Vacuum Pump
Canister Pressure Sensor
Canister Pressure Sensor Vent Valve Fresh Air
To Filter
D13N15
Leak Detection Pump
D13N17
Canister Pump Module
Fresh Air
Vent Valve
Filter Filter
Leak Detection Pump
Canister Pressure
Sensor Filter
To Filter
Reference Orifice
[0.5 mm (0.02 in.) Diameter]
M
P
20
2) Canister Pump Module
Canister pump module consists of the vent valve, canister pressure sensor, and leak detection pump.
The vent valve switches the passages in accordance with the signals received from the ECM.
A DC type brush-less motor is used for the pump motor.
A vane type vacuum pump is used.
Simple Diagram 

NF
NEW FEATURES - 1NZ-FXE ENGINE
01REG03Y
To Intake Manifold
Atmosphere
Purge VSV (Open)
ECM VSV (For Purge Flow Switching Valve)
(OFF)
Canister Pump Module
Vent
Valve
(OFF)
01REG04Y
Purge VSV (Close)
ECM VSV (For Purge Flow Switching Valve)
(OFF)
Vent
Valve
(OFF)
21
System Operation
1) Purge Flow Control
When the engine has satisfied the predetermined conditions (closed loop, engine coolant temperature
above 74C (165F), etc.), the stored vapor gas are purged from the canister whenever the purge VSV
is opened by the ECM.
The ECM will change the duty ratio cycle of the purge VSV, thus controlling purge flow volume. Purge
flow volume is determined by intake manifold pressure and the duty ratio cycle of the purge VSV.
Atmospheric pressure is allowed into the canister to ensure that purge flow is constantly maintained
whenever purge vacuum is applied to the canister.
2) ORVR (On-board Refueling Vapor Recovery)
When the internal pressure of the fuel tank increases during refueling, the vapor gas enters the canister.
Because the vent valve is always open (even when the engine is stopped) when the system is in a mode
other than the monitoring mode, the air that has been cleaned through the canister is discharged outside
the vehicle via the fresh air line. If the vehicle is refueled during the monitoring mode, the ECM will
recognize the refueling by way of the canister pressure sensor, which detects the sudden pressure increase
in the fuel tank, and will open the vent valve.