Toyota Prius+ User manual

Gasoline-Electric
Hybrid Synergy Drive
ZVW4# Series

ii
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.
High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
PRIUS +/PRIUS v to help ensure the high voltage, approximately 201.6 Volt, Lithium-ion (Li-ion)
Hybrid Vehicle (HV) battery assembly is kept safe and secure in an accident.
The Li-ion HV battery assembly contains sealed batteries that are similar to rechargeable batteries used
in some battery operated power tools and other consumer products. The electrolyte is absorbed in the
cell plates and will not normally leak out even if the battery is cracked. In the unlikely event the
electrolyte does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
•Toyota PRIUS +/PRIUS v identification.
•Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle PRIUS +/PRIUS v-electric
vehicles as safely as the dismantling of a conventional non-hybrid automobile.
2012 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.

iii
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................................................................................................................................................7
Hybrid Synergy Drive Operation.............................................................................................................8
Vehicle Operation..........................................................................................................................................8
Hybrid Vehicle (HV) BatteryAssembly andAuxiliary Battery.............................................................9
HV Battery Assembly ....................................................................................................................................9
Components Powered by the HV Battery Assembly.....................................................................................9
HV Battery Assembly Recycling..................................................................................................................10
Auxiliary Battery..........................................................................................................................................10
High Voltage Safety .................................................................................................................................11
High Voltage Safety System........................................................................................................................11
Service Plug Grip........................................................................................................................................12
Precaution to be observed when dismantling the vehicle.....................................................................13
Necessary Items.........................................................................................................................................13
Spills..........................................................................................................................................................14
Dismantling the vehicle ...........................................................................................................................15
Removal of HV battery ...........................................................................................................................19
HV Battery Caution Label ...........................................................................................................................28

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:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery assembly for
the electric motor.
The result of combining these two power sources is improved fuel economy and
reduced emissions. The gasoline engine also powers an electric generator to recharge
the battery assembly; unlike a pure all electric vehicle, the PRIUS +/PRIUS v never
needs to be recharged from an external electric power source.
Depending on the driving conditions one or both sources are used to power the vehicle.
The following illustration demonstrates how the PRIUS +/PRIUS v operates in various
driving modes.
During light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery assembly and drive
to the electric motor.
During full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the wheels to produce electricity that recharges the battery assembly.
While the vehicle is stopped, the gasoline engine and electric motor are off, however
the vehicle remains on and operational.

Starting
Normal Driving

Acceleration

Deceleration

Stopping
Electricity
Electricity and gasoline
Electricity and gasoline
(additional electricity
extracted from batteries)
Charging batteries
Engine automatically
stopped
1/33

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.
Example VIN: JTDZS3EU0C3000101
APRIUS +/PRIUS v is identified by the first 8 alphanumeric characters
JTDZS3EU
.
Left Side Windshield Cowl, Right Side Floor and Left Side Door Pillar
2/33

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

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.
Interior View
Instrument Cluster View

READY Indicator
Shift State Indicator

4/33

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

Hybrid Component Locations & Descriptions
Component Location Description
12 Volt Auxiliary
Battery
Right Side of Cargo
Area
A lead-acid battery that supplies power to the low voltage
devices.
Hybrid Vehicle
(HV) Battery
Assembly
Center Console
201.6 Volt Lithium-ion (Li-ion) battery assembly consisting
of 56 low voltage (3.6 Volt) cells connected in series.
Power Cables
Undercarriage and
Engine
Compartment
Orange colored power cables carry high voltage Direct
Current (DC) between the HV battery assembly,
inverter/converter, and A/C compressor. These cables also
carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motor, and generator.
Inverter/
Converter 
Engine
Compartment
Boosts and inverts the high voltage electricity from the HV
battery assembly to 3-phase AC electricity that drives the
electric motors. The inverter/converter also converts AC
electricity from the electric generator and electric motors
(regenerative braking) to DC that recharges the HV battery
assembly.
Gasoline 
Engine
Engine
Compartment
Provides two functions:
1) Powers vehicle.
2) Powers generator to recharge the HV battery assembly.
The engine is started and stopped under control of the vehicle
computer.
Electric
Motor
Engine
Compartment
3-phase high voltage AC motor contained in the front
transaxle. It is used to power the front wheels.
Electric 
Generator
Engine
Compartment
3-phase high voltage AC generator that is contained in the
transaxle and recharges the HV battery assembly.
A/C Compressor
(with Inverter) 
Engine
Compartment
3-phase high voltage AC electrically driven motor
compressor.
Fuel Tank and Fuel
Line 
Undercarriage and
Center
The fuel tank provides gasoline via a fuel line to the engine.
The fuel line is routed under the center of vehicle.
*Numbers in the component column apply to the illustrations on the following page.
6/33

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:
11.9 gals/45.0 liters
Frame Material:
Steel Unibody
Body Material:
Steel Panels except for Aluminum Hood and Optional Polycarbonate Roof
Seating Capacity:
7 passenger















7/33

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. When illuminated, it informs the driver
that the vehicle is on and operational even though the gasoline engine may be off and
the engine compartment is silent.
Vehicle Operation
•With the PRIUS +/PRIUS v, the gasoline engine may stop and start at any time while the
READY indicator is on.
•Never assume that the vehicle is shut off just because the engine is off. Always look for
the READY indicator status. The vehicle is shut off when the READY indicator is off.
The vehicle may be powered by:
1. The electric motor only.
2. A combination of both the electric motor and the gasoline engine.
Instrument Cluster READY Indicator
8/33

Hybrid Vehicle (HV) BatteryAssembly andAuxiliary 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. The metal case is isolated from high voltage.
•The HV battery assembly consists of 56 low voltage (3.6 Volt) Li-ion battery cells
connected in series to produce approximately 201.6 Volts. Each Li-ion battery cell is
non-spillable and in a sealed case.
•The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The
electrolyte is absorbed into the battery cell separator and will not normally leak, even in a
collision.
HV Battery Assembly
Battery assembly voltage
201.6 V
Number of Li-ion battery cells in the pack
56
Li-ion battery cell voltage
3.6 V
Li-ion battery cell dimensions
4.4 x 0.6 x 4.4 in
(111 x 14 x 112 mm)
Li-ion cell weight
0.55 lbs (0.25 kg)
Li-ion battery assembly dimensions
32.7 x 8.7 x 14.6 in
(830 x 220 x 370 mm)
Li-ion battery assembly weight
69 lbs (31.5 kg)
Components Powered by the HV Battery Assembly
•Electric Motor
•Inverter/Converter Motor
•Power Cables
•A/C Compressor
•Electric Generator
9/33

Hybrid Vehicle (HV) BatteryAssembly andAuxiliary Battery
(Continued)
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. As with
other conventional vehicles, the auxiliary battery is grounded to the metal chassis of the
vehicle.
•The auxiliary battery is located in the cargo area. It is concealed by the deck board and
auxiliary box on the right side in the rear quarter panel well.
201.6 Volt HV Battery Assembly 12 Volt Auxiliary Battery Mounted in Cargo Area
HV BatteryAssembly Mounted in Center Console
HV Battery Assembly
10/33

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. The
inverter/converter creates 3-phase AC to power the motors. Power cables are routed from the
inverter/converter to each high voltage motor (electric motor, electric generator, and A/C
compressor). The following systems are intended to help keep occupants in the vehicle and
emergency responders safe from high voltage electricity:
High Voltage Safety System
•A high voltage fuse * provides short circuit protection in the HV battery assembly.
•Positive and negative high voltage power cables * connected to the HV battery assembly
are controlled by 12 Volt normally open relays *. When the vehicle is shut off, the
relays stop electricity flow from leaving the HV battery assembly.
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.
•Both positive and negative power cables * are insulated from the metal chassis, so there is
no possibility of electric shock when touching the metal chassis.
•A ground-fault monitor continuously monitors for high voltage leakage to the metal chassis
while the vehicle is running. If a malfunction is detected, the hybrid vehicle computer *
will illuminate the hybrid system warning light in the instrument cluster.
•The HV battery assembly relays will automatically open to stop electricity flow in a
collision sufficient to activate the SRS.
*Numbers apply to the illustration on the following page.
11/33

High Voltage Safety (Continued)
Service Plug Grip
•The high-voltage circuit is cut by removing the service plug grip (see page 15).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)







HV Battery Assembly
Inverter/
Converte
r
Hybrid Vehicle Computer
Volts DC
Volts DC
A/C
Compressor
Electric
Generator
Electric
Motor
AC
3-Phase
12 Volt
Auxiliary
Battery
12 Volt
Auxiliary
Battery
HV Battery Assembly
Volts DC
Hybrid Vehicle Computer
Inverter/
Converte
r
Volts DC
AC
3-Phase
Electric
Motor
Electric
Generator
A/C
Compressor
12/33

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.
Necessary Items
•Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
•Insulating tape such as electrical tape that has a suitable electrical insulation rating.
•Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
•An electrical tester that is capable of measuring DC 750 Volts or more.
13/33

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. Any liquid electrolyte that leaks from a Li-ion battery cell quickly
evaporates.
WARNING:
•
The Li-ion battery contains organic electrolyte. Only a small amount may leak
from the batteries which may irritate the eyes, nose, throat, and skin.
• Contact with the vapor produced by the electrolyte may irritate the nose and
throat.
• To avoid injury by coming in contact with the electrolyte or vapor, wear personal
protective equipment for organic electrolyte including SCBA or protective mask
for organic gases.
•Handle Li-ion electrolyte spills using the following Personal Protective Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are not acceptable for electrolyte
spills.
Rubber gloves or gloves suitable for organic solvents.
Apron suitable for organic solvents.
Rubber boots or boots suitable for organic solvents.
Protective mask for organic gases or SCBA.
14/33

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. To prevent
serious injury or death from severe burns or electric shock, avoid
touching, cutting, or opening any orange high voltage power
cable or any high voltage component.
1. Shut off the ignition (READY indicator is
off). Then disconnect the cable from the
auxiliary battery negative (-) terminal.
(1) Remove the 3 deck boards.
(2) Remove the 2 auxiliary boxes.
(3) Disconnect the battery negative terminal.
2. Remove the service plug cover.
(1) Remove the console cover.
(2) Remove the service plug cover.
Front
15/33

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.
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. If the service plug grip cannot be removed due to damage to the vehicle, remove the IG2 fuse
(20 A).
Caution:
This operation shuts off the HV system. Be sure to wear insulated gloves because
high voltage is not shut off inside the HV battery. When it is possible to remove the
service plug grip, remove it and continue the procedure.
IG2 fuse
Front
16/33

7. After disconnecting or exposing a high-voltage
connector or terminal, insulate it immediately using
insulating tape. Before disconnecting or touching
a bare high-voltage terminal, wear insulated gloves.
8. Check the HV battery and nearby area for leakage.
If you find any liquid, it may be Li-ion electrolyte. Handle Li-ion electrolyte spills using the
following Personal Protective Equipment (PPE):
•Splash shield or safety goggles. Fold down helmet shields are not acceptable for electrolyte
spills.
•Rubber gloves or gloves suitable for organic solvents.
•Apron suitable for organic solvents.
•Rubber boots or boots suitable for organic solvents.
•Protective mask for organic gases or SCBA.
Caution:
•The Li-ion battery contains organic electrolyte. Only a small amount may leak from
the batteries which may irritate the eyes, nose, throat, and skin.
•Contact with the vapor produced by the electrolyte may irritate the nose and throat.
•To avoid injury by coming in contact with the electrolyte or vapor, wear personal
protective equipment for organic electrolyte including SCBA or protective mask for
organic gases.
9. If the electrolyte comes into contact with your eye(s), call out loudly for help. Do not rub
your eye(s). 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