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Overall view of the components and their location in a second- generation Toyota Prius.

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Overall view of the components and their location in a second- generation Toyota Prius.

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  1. OBJECTIVESAfter studying Chapter 12, the reader should be able to: 1. Identify a Toyota/Lexus hybrid electric vehicle. 2. Explain the operation of the various unique systems found in Toyota/Lexus hybrid-electric vehicles. 3. List the procedures necessary to disable the high-voltage circuits in Toyota/Lexus hybrid electric vehicles. 4. Describe how to safely perform routine service on a Toyota/Lexus hybrid electric vehicle.

  2. TOYOTA PRIUSThe Prius was first released in Japan in December of 1997 as a 1998 model year.The second-generation Toyota Prius was released in 2003 as a 2004 model.

  3. The second-generation Prius was equipped with Hybrid Synergy Drive. Both generations of the Toyota Prius use a 1.5-liter inline four-cylinder engine that uses the Atkinson cycle to maximize fuel efficiency.

  4. Overall view of the components and their location in a second- generation Toyota Prius.

  5. Dash DisplayThe dashboard on the Prius is mostly digital readouts and icons. There is no tachometer, just a temperature gauge and a fuel level gauge. Near the speedometer is a “READY” light.

  6. Master Warning LightNote the triangle-shaped indicator with the exclamation mark in the middle. This is known as the master warning light.

  7. Energy MonitorThe energy monitor is one of the views available on the large multidisplay.

  8. Consumption screen also shows the average fuel economy over each 5-minute period up to 30 minutes of history.

  9. Smart Entry and Start Electronic Key (Optional Equipment)The second-generation Prius may be equipped with an optional smart entry and start electronic keythat appears similar in function and design to the standard electronic key.

  10. Smart key features include:Passive (remote) function to lock/unlock the doors and start the vehicleWireless transmitter to lock/unlock the doorsElectronic key for startingHidden metal cut key to lock/unlock the doors from the driver door lockBe sure to keep the smart key at least 15 feet from the vehicle when performing repair procedures. This provides an added margin of safety as it will prevent inadvertent starting of the vehicle because the normal range is 10 feet.

  11. When B is selected, the transmission allows the ICE to operate at a higher RPM, causing it to absorb more of the vehicle’s kinetic energy than it would at lower RPMs. Drivers looking for the best fuel mileage should not shift into B unless descending a long, steep grade.

  12. Park on a second-generation Prius is a button rather than a position on the gear selector.

  13. “By-Wire” TechnologyNumerous systems on the Prius have been designed to incorporate by-wire technology.

  14. Brake-by-wire. The brake system on the Prius includes a stroke simulator that provides a normal pedal stroke during regenerative braking. There is also a power source backup unit(second-generation Prius) located next to the auxiliary battery that provides electrical power to the brake system if the 12-volt battery is damaged or disconnected.

  15. Electronic throttle control. The mechanical linkage between the ICE throttle body and the accelerator pedal has been eliminated in favor of electronic control.

  16. Shift-by-wire. A special electronic sensor that responds to both lateral and vertical movement is used as the driver’s shift selector.

  17. Shift control actuator. The only mechanical shifting that takes place in a Prius transmission is the operation of the parking lock mechanism.

  18. Driving a Toyota Hybrid electric VehicleTurning the key (2001-2003 Prius) to the crank position will cause the ICE to start when the “READY” light illuminates or shortly thereafter. If the ICE is already warmed up, the “READY” light will illuminate and the ICE will not start. When the “READY” light is lit, the vehicle is ready to drive, whether the ICE is running or not.

  19. While depressing the brake pedal, press the POWER button once and Prius will go straight to READY mode.

  20. COLD-START EMISSION CONTROLSHC Adsorber and Catalyst (2001-2003 Prius Only)When a catalytic converter is cold, it cannot oxidize HC and CO. The HC Adsorber and Catalyst (HCAC) system utilizes a special catalytic converter assembly that incorporates an HC adsorber to trap and store unburned hydrocarbons during cold starts.Once the catalytic converter is up to operating (light off) temperature, the HCAC bypass valve is opened and HC is purged and sent through the hot catalyst. The bypass valve is also closed during deceleration to purge any remaining HC from the adsorber.

  21. Coolant Heat Storage System (2004 and Later Prius Only)The second-generation Prius did not use the HCAC system. A coolant heat storage system in which heated coolant is stored in a specially designed tank during normal vehicle operation and is then used to warm the engine intake ports prior to a cold start. Warming the intake ports and cylinder head before a cold start helps start the ICE more quickly and reduces HC and CO emissions.

  22. FUEL SYSTEM COMPONENTSIn order to receive certification as a AT-PZEV vehicle, very strict evaporative emission standards must be met.

  23. Bladder Fuel TankBoth generations of the Prius utilize a bladder fuel tank, which stores the fuel in a resin bladder enclosed in a steel shell. The resin bladder can expand and contract with the fuel. Fuel level calculations are based on inputs from a fuel gauge sender and ambient temperature sensor (both located in the tank) plus data from two inclination sensors mounted in the combination meter ECU.

  24. Closed Fuel Tank SystemThe closed fuel tank system is only used on the Highlander hybrid and Lexus RX400h models. A tank close valve (also called a vapor-containment valve) is used to seal the tank and control vapor flow during purge and refueling. An electric fuel door prevents the fuel cap from being removed until the tank pressure has been bled through the charcoal canister and the system is ready for refueling.During this process, the multi-information display reads “PLEASE WAIT NOW OPENING.” When the system has finished depressurizing, it unlocks the fuel door and the display shows “REFUEL READY.”

  25. HIGH-VOLTAGE BATTERY PACKEach NiMH cell produces 1.2 volts; therefore, one module equals 7.2 volts. For the first-generation Prius, 38 modules were installed in series producing 273.6 volts.

  26. Toyota HV Battery Specifications

  27. A first-generation Prius battery pack contains 38 modules, wiring, a system main relay(SMR), computer, a manual disconnect service plug, and a strong metal box to contain everything.

  28. HV Battery CoolingThe high-voltage battery pack is air cooled and utilizes a fan and ducting in the rear of the vehicle for circulating cabin air through the battery assembly. The cooling air can exit outside the vehicle or inside depending on the air pressure in the vehicle cabin.

  29. HV Battery Diagnosis and ServiceThe warranty of the battery pack varies by manufacturer but typically is covered for eight years or 100,000 miles.Environmental concerns regarding battery disposal were addressed prior to releasing hybrids in the United States by requiring a “cradle-to-grave” process. An 800 telephone number is located on the battery case or under the hood, and this number should be called when an end-of-life NiMH battery assembly needs to be recycled.

  30. Replacing the HV Battery PackWhen replacing a battery pack, the entire box is replaced as a unit. It weighs about 115 lbs (52 kg) and should be handled carefully as high voltage is contained inside.The high-voltage battery system must be disabled before attempting any system repairs. Be sure to wear the appropriate personal protective equipment (PPE) and follow the manufacturer-specified procedures.

  31. THE TOYOTA HYBRID SYSTEMThe Toyota Hybrid System (THS), as used in both generations of the Prius, consists of one planetary gearset and two electric machines. The planetary gearset is known as a power-split device, because it splits power from the ICE and uses it for moving the vehicle and for generating electrical power.

  32. One electric machine is attached to the planetary sun gear and is called motor-generator 1 (abbreviated MG1). The second electric machine is attached to the planetary ring gear and is labeled motor-generator 2 (abbreviated MG2). The ICE is also connected to the planetary gearset through the planet carrier.

  33. During operation, each motor-generator fulfills two primary functions:MG1 is used to start the internal combustion engine and generate electricity for charging the high-voltage batteries, as well as driving MG2.MG2 is used to propel the vehicle and generate electricity during slowing and braking (regenerative braking). MG2 is connected directly to the drive wheels at all times.

  34. Four-wheel-drive versions of the Highlander Hybrid and Lexus RX400h use a third electric machine known as MGR. MGR is connected to the rear wheels and is used to propel the vehicle forward and backward as well as for regenerative braking.

  35. Inverter AssemblyControl of the motor-generators in the Toyota Hybrid System is accomplished using the inverter assembly located in the ICE compartment.

  36. 1. Inverter. Converts high-voltage DC into three-phase AC to power MG1, MG2, and MGR.2. DC-DC converter. Converts high-voltage DC to 12-VDC to power the vehicle auxiliary systems.3. Boost converter.4. A/C compressor inverter.5. Cooling system.

  37. LEXUS RX400h/TOYOTA HIGHLANDER HYBRIDThe Lexus RX400h is a strong hybrid, which means that it is capable of operating in electric-only or gas-engine-only mode, as well as a mode that combines the power of the gas engine and electric motor.

  38. The hybrid system uses a 288-volt DC nickel metal hydride (Ni-MH) battery pack that is located under the rear seat.

  39. The battery power is directed through a boost converter that raises the voltage to 650 volts DC. An inverter changes this to 650 volts AC for use by a front-mounted 123-kW electric motor that turns as high as 12,400 RPM.

  40. The RX 400h four-wheel drive (4WD) system uses a separate 50-kW electric motor (MGR) at the rear that provides up to 96 lb-ft of additional drive torque. MGR is integrated into the rear-drive unit with a differential in an independent rear suspension configuration. The system electronically varies front and rear torque distribution depending on traction conditions.

  41. Vehicle Dynamic Integrated Management (VDIM)VDIM also interfaces with the Electronic Throttle Control (ETC) system and the Electronic Power Steering (EPS) system to optimize steering assist for each situation.

  42. The EPS uses a brushless-type DC motor and gear reduction system built into the steering gear housing to provide steering assist.

  43. Driving the RX 400hAll of the comfort and luxury found inside the RX 330 is present in the RX 400h, with a few changes, including:In place of a traditional tachometer, the RX 400h has a power meter that displays the level of power generated by the hybrid power train. The driver can also monitor the gas-electric power distribution on the multi-information display or on the optional navigation system's 7-inch touch-panel display screen.

  44. TOYOTA CAMRY HYBRIDThe Toyota Camry Hybrid features a 2.4-liter inline four-cylinder ICE using the Atkinson cycle. The Camry Hybrid is a front-wheel-drive THS II configuration. The package includes a 105-kW electric motor and a high-voltage battery pack that delivers a peak of 45 hp.

  45. The high-voltage battery pack produces 244 volts and consists of 34 nickel metal hydride modules, each of which contains six 1.2-volt cells. The battery pack is located behind the rear passenger seat backs.

  46. The 12-volt auxiliary battery is located on the passenger side of the trunk area.The inverter assembly incorporates a boost converter that raises the 244 volts DC from the battery pack to 650 volts DC for higher motor efficiency.

  47. LEXUS GS450hThe Lexus GS450h is a rear-wheel-drive sedan using a V-6 ICE and a Hybrid Synergy Drive transmission. The transmission incorporates a power-split planetary gear unit along with a two-stage motor speed reduction planetary. The second planetary can switch between two ranges and will vary the speed of MG2 according to vehicle speed and torque requirements.

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