Toyota Prius, Plug-in Hybrid 2010, 2010 PRIUS, 2012 PRIUS User Manual

Plug-in Hybrid

2010 Model

Revised (includes 2012 Model)

© 2012 Toyota Motor Corporation
All rights reserved. This document may not be
altered without the written permission of Toyota Motor Corporation.

Prius Plug-in hybrid ERG REV A – (02/22/12)

F

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oreword

This Prius Plug-in hybrid Emergency Response Guide has been revised
to include the changes of the 2012 model year Prius Plug-in hybrid.
These changes include minor updates to the vehicle exterior, interior
and hybrid system. The important changes affecting the emergency
responder are the reshaped high voltage battery assembly, HV battery
voltage, and location of charge inlet door. While many features of the
Prius Plug-in hybrid are shared with the 2010 3rd generation Prius
hybrid, emergency responders should recognize and understand the
new features of the Prius Plug-in hybrid covered in this guide.

High voltage electricity powers the electric motor, generator, air
conditioning compressor and inverter/converter. All other automotive
electrical devices such as the headlights, radio, and gauges are powered
from a separate 12 Volt system. Numerous safeguards have been
designed into the Prius Plug-in hybrid to help ensure the high voltage,
approximately 346 *1/207.2 *2 Volt, Li-ion Hybrid Vehicle (HV)
battery assembly is kept safe and secure in an accident.

*1: 2010 Model
*2: 2012 Model

The 2010 Model Prius Plug-in hybrid utilizes the following electrical
systems:

• Maximum 650 Volts AC

• Nominal 346 Volts DC

• Nominal 120/240 Volts AC

• Maximum 27 Volts DC

• Nominal 12 Volts DC

The 2012 Model Prius Plug-in hybrid utilizes the following electrical
systems:

• Maximum 650 Volts AC

• Nominal 207.2 Volts DC

• Nominal 120/240 Volts AC

• Maximum 27 Volts DC

• Nominal 12 Volts DC

2010 Model Prius Plug-in hybrid features:

• An electric vehicle charge cable rated at 120 Volts.

• An onboard battery charger with a 120 Volt /240 Volt AC input and

346 Volt DC output.

• A boost converter in the inverter/converter that boosts the available

voltage to the electric motor to 650 Volts.

• A high voltage Hybrid Vehicle (HV) Li-ion battery assembly rated

at 346 Volts.

• A high voltage motor driven Air Conditioning (A/C) compressor

rated at 346 Volts and a heat pump type remote air conditioning
system.

• A body electrical system rated at 12 Volts, negative chassis ground.

• Supplemental Restraint System (SRS) – dual stage frontal airbags,

front seat mounted side airbags, side curtain airbags, front seatbelt
pretensioners, and driver knee airbag.

2012 Model Prius Plug-in hybrid features:

• An electric vehicle charge cable rated at 120 Volts.

• An onboard battery charger with a 120 Volt /240 Volt AC input and

207.2 Volt DC output.

• A boost converter in the inverter/converter that boosts the available

voltage to the electric motor to 650 Volts.

• A high voltage Hybrid Vehicle (HV) Li-ion battery assembly rated

at 207.2 Volts.

• A high voltage motor driven Air Conditioning (A/C) compressor

rated at 207.2 Volts and remote air conditioning system.

• A body electrical system rated at 12 Volts, negative chassis ground.

• Supplemental Restraint System (SRS) – dual stage frontal airbags,

front seat mounted side airbags, side curtain airbags, front seatbelt
pretensioners, and driver knee airbag.

High voltage electrical safety remains an important factor in the
emergency handling of the Prius Plug-in Hybrid Synergy Drive. It is
important to recognize and understand the disabling procedures and
warnings throughout the guide.

F

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oreword (Continued)

Additional topics in the guide include:

The following indicates the key identification points for each model.
Make sure to identify the target vehicle using this and refer to the
corresponding rescue methods.

• Prius Plug-in hybrid identification.

•

Major Hybrid Synergy Drive component locations and descriptions.

•

Extrication, fire, recovery, and additional emergency response
information.

Key Identification Points:

•

Roadside assistance information.

The main difference is that the charge inlet door has been relocated
from the driver side front fender to the passenger side rear quarter
panel.

2012 Model Year Prius Plug-in Hybrid 2010 Model Year Prius Plug-in Hybrid

Charge Inlet Door

2010 Model

This guide is intended to assist emergency responders in the safe
handling of a Prius Plug-in hybrid vehicle during an incident.

NOTE:

Emergency Response Guides for Toyota hybrid and alternative fuel
vehicles may be viewed at http://techinfo.toyota.com.

2012 Model

Charge Inlet Door

Charge Inlet Door

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Table of Contents (2010 Model) Page

About the Prius Plug-in Hybrid 1
Prius Plug-in Hybrid Identification 2
Hybrid Synergy Drive Component Locations & Descriptions 5
Plug-in Charging System Component Locations & Descriptions 8
Smart Key System 9
Electronic Gearshift Selector 11
Hybrid Synergy Drive Operation 12

Hybrid Vehicle (HV) Battery Assembly 13

Plug-in Charging System 14
Remote Air Conditioning System 16
Low Voltage Battery 18
High Voltage Safety 19
Plug-in Charging Safety 20
SRS Airbags & Seat Belt Pretensioners 22
Emergency Response 24
Extrication 24

Fire 31
Overhaul 32
Recovery of Li-ion HV Battery Assembly 32
Spills 33
First Aid 33
Submersion 34

Table of Contents (2010 Model) Page

Roadside Assistance 35

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Table of Contents (2012 Model) Page

About the Prius Plug-in Hybrid 39
Prius Plug-in Hybrid Identification 40
Hybrid Synergy Drive Component Locations & Descriptions 43
Plug-in Charging System Component Locations & Descriptions 46
Smart Key System 47
Electronic Gearshift Selector 49
Hybrid Synergy Drive Operation 50

Hybrid Vehicle (HV) Battery Assembly 51

Plug-in Charging System 52
Remote Air Conditioning System 54
Low Voltage Battery 55
High Voltage Safety 56
Plug-in Charging Safety 57
SRS Airbags & Seat Belt Pretensioners 59
Emergency Response 61
Extrication 61

Fire 68
Overhaul 69
Recovery of Li-ion HV Battery Assembly 69
Spills 70
First Aid 70
Submersion 71

Table of Contents (2012 Model) Page

Roadside Assistance 72

About the Prius Plug-in Hybrid (2010 Model)

The Prius Plug-in hybrid contains a gasoline engine, an electric motor,
and a newly developed large capacity Li-ion battery. It is the first
Toyota hybrid that allows the HV battery to be plugged-in and charged
by an external power source. Two power sources are stored on board
the vehicle:

When the HV battery is discharged the vehicle operates in Hybrid Vehicle
mode

1. Gasoline stored in the fuel tank for the gasoline engine.

2. Electricity stored in a large capacity externally chargeable high
voltage Hybrid Vehicle (HV) battery assembly for the electric
motor.

HV (Hybrid Vehicle) Mode:

 During light acceleration at low speeds, the vehicle is powered by

the electric motor. The gasoline engine is shut off.

Depending on the driving conditions, one or both sources are used to
power the vehicle. The following illustration demonstrates how the
Prius Plug-in hybrid operates in various driving modes.



During normal driving, the vehicle is powered mainly by the
gasoline engine. The gasoline engine also powers the generator to
recharge the HV battery assembly and to drive the electric motor.

Plug-in EV (Electric Vehicle) Mode:



During full acceleration, such as climbing a hill, both the gasoline
engine and the electric motor power the vehicle.

 Utilizing the charge cable assembly connected to a 120 Volt outlet,

the vehicle’s HV battery can be charged within 3 hours.



During deceleration, such as when braking, the vehicle regenerates
the kinetic energy from the front wheels to produce electricity that
recharges the HV battery assembly.



When the HV battery is sufficiently charged, the vehicle will
basically run on the power of the electric motor for approximately
13 miles.



While the vehicle is stopped, the gasoline engine and electric motor
are off, however the vehicle remains on and operational.



If the vehicle exceeds approximately 60 mph (100 km/h) or
accelerates suddenly when traveling in plug-in EV mode, the
gasoline engine and electric motor work together to power the
vehicle.

 Normal Driving

-

1-

Plug-in charging

Electricity Electricity and gasoline Electricity and gasoline Electricity

Electricity and gasoline
(Additional electricity
extracted from batteries)

Charging batteries

Engine automatically stopped

 Hard Acceleration

 Starting  Normal Driving  Acceleration  Deceleration  Stopping  Plug-in Charging

Exceeds
Approximately 60 mph (100 km/h)

Plug-in EV Mode HV (Hybrid Vehicle) Mode

Prius Plug-in Hybrid Identification (2010 Model) Prius Plug-in Hybrid Identification (2010 Model)

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In appearance, the 2010 model year Prius Plug-in hybrid is a 5-door
hatchback. Exterior, interior, and engine compartment illustrations are
provided to assist in identification.

In appearance, the 2010 model year Prius Plug-in hybrid is a 5-door
hatchback. 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 and on the driver door pillar.

The alphanumeric 17 character Vehicle Identification Number (VIN) is
provided in the front windshield cowl and on the driver door pillar.

Example VIN: JTDKN3DPExample VIN: JTDKN3DPA82020211

A Prius Plug-in hybrid is identified by the first 8 alphanumeric characters
JTDKN3DP.

Driver Side Windshield and Driver Side B Pillar

Exterior

 and logos on the hatch.
 logo on the passenger side front fender.

 Charge inlet door with logo, located on the driver side front

fender.

 Plug-in Hybrid decals located on the sides of the vehicle.

Exterior Driver Side View

Exterior Front and Rear View

Exterior Rear and Driver Side View



















Prius Plug-in Hybrid Identification (2010 Model ­Continued)

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Interior

Interior View

Instrument Cluster View





An instrument cluster (speedometer, READY light, shift position indicators,

warning lights) located in center of the dash and near the base of the
windshield.

 A plug-in charge indicator light located on the upper dash near the driver

side windshield.







Prius Plug-in Hybrid Identification (2010 Model ­Continued)

Prius Plug-in Hybrid Identification (2010 Model ­Continued)

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Engine CompartmentEngine Compartment

Engine Compartment View





1.8-liter aluminum alloy gasoline engine.

 Logo on the plastic engine cover.



Hybrid Synergy Drive Component Locations &
Descriptions (2010 Model)

Hybrid Synergy Drive Component Locations &
Descriptions (2010 Model)

-5-

Component Location Description

12 Volt 
Auxiliary Battery

Passenger Side
of Cargo Area

A lead-acid battery that supplies power to the

low voltage devices.
Hybrid  Vehicle
(HV) Battery
Assembly

Cargo Area 346 Volt Lithium-ion (Li-ion) battery pack

consisting of 3.6 Volt cells connected in a

series-parallel circuit.
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 motor. The

inverter/converter also converts AC

electricity from the electric generator and

electric motor (regenerative braking) to DC

that charges the HV battery assembly.
Gasoline 
Engine

Engine
Compartment

Provides two functions:

1) Powers vehicle.

2) Powers generator to charge 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 charges the

HV battery assembly.
A/C Compressor
(with Inverter) 

Engine
Compartment

3-phase high voltage AC electrically driven

motor compressor.

Hybrid Synergy Drive Components















Components (Top View) and High Voltage Power Cables

















Hybrid Synergy Drive Component Locations &
Descriptions (2010 Model - Continued)

Hybrid Synergy Drive Component Locations &
Descriptions (2010 Model - Continued)

-6-

Component Location Description

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.

Fuel Tank and Fuel Line



Hybrid Synergy Drive Component Locations &
Descriptions (2010 Model - Continued)

Hybrid Synergy Drive Component Locations &
Descriptions (2010 Model - Continued)

Key Specifications:Key Specifications:

-7-

Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine

Electric Motor: 80 hp (60 kW), AC Motor

Transmission: Automatic Only (electrically controlled

continuously variable transaxle)

HV Battery Assembly: 346 Volt Sealed Li-ion

Battery

Curb Weight: 3,362 lbs/1,525 kg

Fuel Tank: 10.6 gals/40.0 liters

Frame Material: Steel Unibody

Body Material: Steel Panels except for Aluminum Hood and

Hatch

Seating Capacity: 5 passenger

Steel Unibody

Aluminum Hood

Aluminum Hatch

P

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lug-in Charging System Component Locations &

Descriptions (2010 Model)

Component Location Description

Charge Inlet  Driver Side Front

Fender

Connects to the charge cable assembly

charge connector. Supplies the electrical

power from an external power source to the

vehicle.

Power Cable
for Charging


Driver Side
behind front
fender

Power cable connecting the charge inlet and

charger assembly.

Charger
Assembly 

Under Front
Passenger Seat

Boosts the AC power supplied from an

external power source and converts it to DC

to charge the HV battery assembly and

operate the A/C compressor.

Charge Cable
Assembly 

Driver Side Front
Fender

Connects to the charge inlet and supplies

power from an external power source to the

vehicle.

Charge
Indicator 

Upper Dash near
Driver Side
Windshield

Illuminates, flashes, or goes off to indicate

the plug-in charging status. Also

illuminates to indicate the operation of the

remote air conditioning system.

Plug-in Charging System Components

Components (Top View) and Charge Inlet Power Cables















S

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mart Key System (2010 Model)

The Prius Plug-in hybrid smart key system consists of a smart key
transceiver that communicates bi-directionally, enabling the vehicle to
recognize the smart key in proximity to the vehicle. Once recognized,
the smart key will allow the user to lock and unlock the doors without
pushing smart key buttons, and start the vehicle without inserting it into
an ignition switch.

Smart key features:

•

Passive (remote) function to lock/unlock the doors and start the
vehicle.

•

Wireless transmitter buttons to lock/unlock all 5 doors.

•

Hidden metal cut key to lock/unlock the doors.

Door (Lock/Unlock)

There are several methods available to lock/unlock the doors.

• Pushing the smart key lock button will lock all doors including the hatch.
Pushing the smart key unlock button once unlocks the driver door, twice
unlocks all doors.

• Touching the sensor on the backside of the driver door exterior handle, with
the smart key in proximity to the vehicle, unlocks the driver door.
Touching the sensor on the backside of the front passenger door exterior
handle, with the smart key in proximity to the vehicle, unlocks all doors.
Touching the lock sensor on either front door, or the lock button for the
hatch will lock all doors.

• Inserting the hidden metal cut key in the driver door lock and turning
clockwise once unlocks the driver door, twice unlocks all doors. To lock
all doors turn the key counter clockwise once. Only the driver door
contains an exterior door lock for the metal cut key.

Smart Key (Fob) Hidden Metal Cut Key for Door Lock

Driver Door Unlock Touch Sensor and

Lock Touch Sensor

Front Driver Door Lock

Hatch Lock Button

Release Button

Unlock Touch Sensor

Use the Hidden Metal Cut Key

Lock Touch Sensor

S

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mart Key System (2010 Model - Continued)

Vehicle Starting/Stopping

The smart key has replaced the conventional metal cut key, and the power
button with an integral status indicator light has replaced the ignition switch.
The smart key only needs to be in proximity to the vehicle to allow the system
to function.

• With the brake pedal released, the first push of the power button operates
the accessory mode, the second push operates the ignition-on mode, and the
third push turns the ignition off again.

Ignition Mode Sequence (brake pedal released):

• Starting the vehicle takes priority over all other ignition modes and is
accomplished by depressing the brake pedal and pushing the power button
once. To verify the vehicle has started, check that the power button status
indicator light is off and the READY light is illuminated in the instrument
cluster.

• If the internal smart key battery is dead, use the following method to start
the vehicle.

1. Touch the Toyota emblem side of the smart key to the power button.

2. Within the 5 seconds after the buzzer sounds, push the power button

with the brake pedal depressed (the READY light will illuminate).

• Once the vehicle has started and is on and operational (READY-ON), the
vehicle is shut off by bringing the vehicle to a complete stop and then
depressing the power button once.

• To shut off the vehicle before coming to a stop in an emergency, push and
hold down the power button for more than 3 seconds. This procedure may
be useful such as at an accident scene in which the READY indicator is on
and the drive wheels remain in motion.

Ignition Mode

Power Button Indicator Light

Off Off

Accessory Amber

Ignition-On Amber

Brake Pedal Depressed Green

Vehicle Started (READY-ON) Off

Malfunction Blinking Amber

Power Button with Integral Status

Indicator Light

Ignition Modes (Brake Pedal Released)

Starting Sequence

(Brake Pedal Depressed)

Smart Key Recognition

(When Smart Key Battery is Dead)

Accessory

Ignition-On

Vehicle Of

f

Button Push

Button Push

Button Push

-11-

Electronic Shift Selector (2010 Model)

The Prius Plug-in hybrid electronic shift selector is a momentary select
shift-by-wire system that can be used to select reverse (R), neutral (N),
drive (D), or engine brake (B) states.

• These states may only be selected while the vehicle is on and operational
(READY-on), except for neutral (N) which may also be selected while in
the ignition-on mode. After R, N, D, or B is selected, the transaxle remains
in that state, identified on the instrument cluster, but the shift selector
returns to the home position. To select neutral (N), it is necessary to hold
the shift selector in the N position for approximately 0.5 seconds.

• Unlike a conventional vehicle, the electronic shift selector does not contain
a park (P) position. Instead, a separate P position switch located above the
shift selector selects park (P).

• When the vehicle is stopped, regardless of shift state, the electro­mechanical parking lock pawl is engaged to lock the transaxle into park (P)
by either pressing the P position switch or pressing the power button to shut
off the vehicle.

• Being electronic, the shift selector and park (P) systems depend on the low
voltage 12 Volt auxiliary battery for power. If the 12 Volt auxiliary battery
is discharged or disconnected, the vehicle cannot be started and cannot be
shifted into or out of park (P). There is no manual override except to
reconnect the auxiliary battery or jump start the vehicle, refer to Jump
Starting on page 38.

Electronic Shift Selector and P Position Switch

Home
Position

Instrument Cluster Shift State Indicator

Indicates
Gear Positio

n

H

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ybrid Synergy Drive Operation (2010 Model)

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 lit, 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 Plug-in hybrid, 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 and instrument cluster lights are off.

• The vehicle may be powered by:

1. The electric motor only.

2. A combination of both the electric motor and the gasoline engine.

• The vehicle computer determines the mode in which the vehicle operates in
order to improve fuel economy and reduce emissions. The Prius Plug-in
hybrid features plug-in EV (Electric Vehicle) mode, a mode that is
automatically selected when the HV battery is charged using an external
power source. Power and ECO (Economy) modes are driver selectable.

1. ECO Mode: When activated, this mode helps enhance fuel
economy on trips that involve frequent braking and acceleration.

2. Power Mode: Optimizes acceleration feel by increasing the power
output more quickly at the beginning of accelerator pedal
operation.

Instrument Cluster READY Indicator

Economy Drive Mode Switch/Power Mode Switch

H

-13-

ybrid Vehicle (HV) Battery Assembly (2010 Model)

The Prius Plug-in hybrid features a large capacity high voltage Hybrid
Vehicle (HV) battery assembly that contains newly developed 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 lower part of the cargo area behind the rear seat. The metal case is
isolated from high voltage and concealed by a carpeted panel in the cabin
area.

• The HV battery assembly consists of 3.6 Volt Li-ion battery cells connected
in series-parallel circuit to produce approximately 346 Volts. Each Li-ion
battery cell is non-spillable and contained in a sealed metal 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.

Components Powered by the HV Battery Assembly

HV Battery Assembly Recovery

• If recovery of the HV battery assembly is necessary, please contact:

United States: [phone]
Canada: (888) TOYOTA 8 [[phone]]

HV Battery Assembly

HV Battery Assembly

Battery assembly voltage

346 V

Number of Li-ion battery cells in the battery

96 cells

Li-ion battery cell voltage

3.6 V

Li-ion battery cell dimensions

4.42 x 4.35 x 0.56 in.

(112.2 x 110.6 x 14.1 mm)

Li-ion cell weight

0.54 lbs (245 g)

Li-ion battery assembly dimensions

32.4 x 38.1 x 14.9 in.

(822.4 x 967.8 x 378.4 mm)

Li-ion battery assembly weight

333 lbs (151.1 kg)

•

Electric Motor

•

Inverter/Converter

• Power Cables • A/C Compressor

• Electric Generator

Pl

-14-

ug-in Charging System (2010 Model)

The plug-in charging system uses an on-board charger to convert AC power
supplied via the charge cable assembly to DC power that can be used to charge
the HV battery assembly. The charging system uses refined charging control to
ensure battery durability and prevent fires due to overcharging.

The utility power supplied by the charge cable assembly is converted by the
onboard charger assembly to the approximately 346 Volts DC used to charge
the HV battery assembly.

Prius Plug-in hybrid vehicles for North America are supplied with a charge
cable assembly designed to allow charging from a 120 Volt AC NEMA 5-15R
receptacle. The maximum current flow during charging is 12 A.

NOTE:
The Prius Plug-in hybrid is compatible with aftermarket chargers or Electric
Vehicle Supply Equipment (EVSE) available from different manufacturers
other than Toyota. Some EVSE’s are available with 240 Volt input for quicker
charging.

Safety Concerns
Since the operation of the plug-in charging system allows high voltage
electrical flow when the vehicle is shut off, it is important to recognize how the
system is activated, deactivated, and disabled.

System Activation:
The following steps provide a simplified explanation on how to charge the
vehicle.

1. Confirm that the vehicle is off and in park (P).

2. Connect the charge cable assembly to a suitable 120 Volt wall
receptacle.

3. Confirm the presence of power, and test the CCID (Charging Circuit
Interrupter Device).

4. Connect the charge cable assembly to the vehicle charge inlet
connector.

5. Confirm that the vehicle’s charge indicator illuminates.

When charging, the high voltage cables are energized. Utility electricity flows
from the charge inlet, its voltage is then boosted and it is provided to the HV
battery assembly and air conditioning compressor. Charging normally
completes within 3 hours and will stop automatically.

Charge Cable Assembly and Charge

Indicator

CHARGE Indicator, TEST Button

and RESET Button

Plug-in Charging System Operation (READY Indicator Off)

Charge Indicator

DC Flow
(Charger to
Battery)

AC Flow
(Inlet to Charger)

HV Battery Assembly

Charge Inlet

-15-

Plug-in Charging System (2010 Model - Continued)

System Deactivation:
The following steps explain how to stop charging.

1. Disconnect the charge cable assembly connector from the vehicle.
To disconnect it, push the orange lock release button on the top of
the connector and pull it away from the vehicle.

2. Close the charge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the
electrical outlet.

Disconnect Charge Cable Connector

Close Charge Inlet Cap and Charge

Inlet Door

Disconnect Plug Remove Battery Cover

Remove Tire Repair Kit and Foam Insert

When the charging system is deactivated, high voltage cables are de­energized and the high voltage electrical flow stops in the charge cable
assembly and vehicle.

WARNING:

The high voltage system, including the charging system, may remain
powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns or
electric shock, avoid touching, cutting, or breaching any orange high
voltage power cable or high voltage component.

System Disabling:
To disable the charging system, disconnect the 12 Volt auxiliary battery
after performing the above deactivation procedure.

12 Volt Auxiliary Battery

-16-

Remote Air Conditioning System (2010 Model)

The following points can be used to confirm that the remote air
conditioning system is operating:

The remote air conditioning system is provided to enhance occupant comfort by
heating or cooling the vehicle interior while the vehicle is shut off and the
charge cable assembly is plugged in.

The remote air conditioning system is similar to a remote engine start system
used in a conventional gasoline vehicle to precondition the vehicle interior
while the vehicle is parked. Unlike a conventional gasoline vehicle, the Prius
Plug-in hybrid does not start the gasoline engine. Instead, to heat or cool the
vehicle interior, it utilizes power from the charge cable assembly to operate the
high voltage air conditioning compressor. The compressor operates in a
conventional manner for cooling, and it operates as a heat pump for heating.
The system can only be activated remotely by pushing the smart key A/C
button and will operate for up to 30 minutes when certain conditions are met.

Safety Concerns
Since the operation of the remote air conditioning system allows high voltage
electrical flow, it is important to recognize how the system is activated,
deactivated, and disabled.

System Activation:
When the remote air conditioning system is activated, the high voltage cables
are energized. Household electricity flows from the charge inlet, its voltage is
then boosted and it is provided to the HV battery assembly and air conditioning
compressor. The system can operate when all of the following operating
conditions are met:

• The charge cable assembly is connected.

• The doors and hood are closed.

• The vehicle Power switch is off.

• The brake pedal is not being depressed.

• The shift position is park (P).

• The charge level of the HV battery assembly is above a specified level.

• There is a difference between the set temperature and actual cabin

temperature.

• Air is flowing from the interior vehicle vents, and blower fan noise or
compressor noise is heard.

• The charge cable assembly is connected and the charge indicator is
illuminated.

• The instrument cluster lights are on, the READY indicator is off, and
all of the conditions in the preceding list are met.

Charge Indicator

Charge Cable Assembly and Charge

Indicator

Remote Air Conditioning System A/C

Button

Remote Air Conditioning System Operation (READY Indicator Off)

A/C Button

Charge Cable
Assembly

12 Volt Auxiliary

Battery

Air Conditioning

Compressor

Charger Assembly

DC Flow

DC Flow

AC Flow

HV Battery Assembly

Charge Inlet

-17-

Remote Air Conditioning System (2010 Model -Continued)

System Deactivation:
When the system is deactivated, the A/C system stops. The system is
deactivated when any one of the following conditions occurs:

• When the system has operated for more than about 30 minutes.

• When the vehicle interior nears the set temperature.

• When a door is opened, the hood is opened, or the brake pedal is

depressed.

• When the smart key A/C button is pushed twice within 3 seconds.

• When the operating conditions are not met.

NOTE:

• It is not possible to operate the remote A/C system and perform plug in
charging of the HV battery assembly at the same time. If plug in
charging is being performed and the remote A/C system is turned on,
plug in charging will stop.

• Plug in charging will not resume after the remote A/C system
deactivates.

WARNING:

The high voltage system, including the charging system, may remain powered
for up to 10 minutes after the vehicle is shut off, disabled, charging stops, or the
remote A/C system stops. To prevent serious injury or death from severe burns
or electric shock, avoid touching, cutting, or breaching any orange high
voltage power cable or high voltage component.

System Disabling:
Operation of the remote air conditioning system can be disabled by
disconnecting the charge cable assembly (see page 15 for illustration). Perform
the following steps to remove the charge cable assembly.

1. Disconnect the charge cable assembly connector from the vehicle.
To disconnect it, push the orange lock release button on the top of
the connector and pull it away from the vehicle.

2. Close the charge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the
electrical outlet.

-18-

Low Voltage Battery (2010 Model)

Auxiliary Battery

• The Prius Plug-in hybrid contains a sealed lead-acid 12 Volt battery. The
12 Volt auxiliary battery powers the vehicle’s electrical system similar to a
conventional vehicle. As with conventional vehicles, the negative terminal
of 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 a fabric
cover, tire repair kit, and foam insert on the passenger side in the rear
quarter panel well.

NOTE:
An under hood label shows the location of the HV battery assembly
(traction battery) and 12 Volt auxiliary battery.

Remove Auxiliary Battery Cover

Remove Tire Repair Kit and Foam

Insert

Battery Location Label

12 Volt Auxiliary Battery

H

-19-

igh Voltage Safety (2010 Model)

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 HV battery assembly, under the vehicle floor pan, to the
inverter/converter. The inverter/converter contains a circuit that boosts the HV
battery voltage from 346 to 650 Volts DC. The inverter/converter creates 3­phase AC to power the motor. 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

• High voltage fuses  provide 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 and not charging, the relays stop electrical flow from
leaving the HV battery assembly.

WARNING:

The high voltage system, including the charging system, may remain
powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns
or electric shock, avoid touching, cutting, or breaching any orange
high voltage power cable or high voltage component.

• Both positive and negative power cables  are insulated from the metal
body. High voltage electricity flows through these cables and not through
the metal vehicle body. The metal vehicle body is safe to touch because it
is insulated from the high voltage components.

• 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 master warning

light

in the instrument cluster and indicate “Check Hybrid System” on

the multi-information display.

High Voltage Safety System – Vehicle Shut Off (READY-OFF)

High Voltage Safety System – Vehicle On and Operational (READY-ON)

Hybrid Vehicle Computer



00

Volt DC

12 Volt
Auxiliary
Battery



A/C
Compressor



Electric
Generator

Inverter/



Converter

00

Electric
Motor

Volt DC



00

Volt AC Volt DC

AC

00

3-Phase



Battery Charger
Assembly

HV Battery Assembly

Hybrid Vehicle Computer

346

Volt DC

12 Volt
Auxiliary
Battery

A/C
Compressor

Electric
Generator

Inverter/
Converter

HV Battery Assembly

AC
3-Phase

Electric
Moto

r

Volt DC

346

Volt AC

Volt AC

Volt DC

AC

00

Battery Charger
Assembly

00

3-Phase

Plug-in Charging Safety (2010 Model)

The HV battery assembly can be charged using power from an external power
outlet. AC power is supplied to the charge inlet by the charge cable assembly
and sent to the charger assembly. There are basically 2 circuits in the charger
assembly: One is an AC/DC converter circuit and the other is a booster circuit
used to boost the charger input voltage to 346 Volts. DC power from the
charger assembly is used to charge the HV battery assembly. To provide
information about charging or remote air conditioning status, the hybrid vehicle
computer illuminates the charge indicator on the instrument panel pad during
charging and when the remote air conditioning system is on.
When remote air conditioning system operation or charging completes, relays
are opened to stop charging system high voltage power flow.

The following systems are intended to help keep vehicle occupants and
emergency responders safe from high voltage electricity:

Plug-in Charging System Safety System

• The hybrid vehicle computer monitors the charging system based on
information from various sensors. If the hybrid vehicle computer detects a
malfunction, charging is stopped, relays are opened, and the charge
indicator flashes to indicate the presence of the malfunction.

WARNING:

The high voltage system, including the charging system, may remain
powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns or
electric shock, avoid touching, cutting, or breaching any orange high
voltage power cable or high voltage component.

-20-

P

-21-

lug-in Charging Safety (2010 Model - Continued)

• The AC cables  are connected to the charger assembly. The high voltage
DC power cables from the charger assembly  are connected to the HV
battery assembly and are controlled by 12 Volt normally open charge relays
, HV system main relays  and AC leakage cut relays . When
charging is not being performed, or the remote air conditioning system is
not operating, the charge relays  and HV system main relays  electrical
flow from the HV battery assembly to the charger assembly, and the relays
in the CCID (Charging Circuit Interrupter Device)  stop the supply of
household power to the vehicle.

• Both the high voltage power cables  and the AC cables 

are insulated

from the metal body. High voltage electricity flows through these cables
and not through the metal vehicle body. The metal vehicle body is safe to
touch because it is insulated from the high voltage components.

• Ground fault monitors  and  continuously monitor for high voltage
leakage to the metal chassis while the vehicle is charging. If a malfunction

is detected, the CCID will illuminate its error light

.

• The CCID contains a power light, an error light

, a TEST button, and a
reset button. When the charge cable assembly is connected to a 120 Volt
outlet, the power light illuminates. The TEST and RESET buttons function
like a conventional residential GFCI (Ground Fault Circuit Interrupter).
Pushing the TEST button opens the CCID relays, and pushing the RESET
button resets the circuit.

Plug-in Charging System – Charging

Plug-in Charging System – Charge Completed or Malfunctioning

Hybrid Vehicle Computer





















Battery Charger
Assembly

12V Auxiliary
Battery

HV Battery
Assembl

y

Charging Circuit Interrupter
Device (CCID

)

12V Auxiliary
Battery

Charging Circuit Interrupter
Device

(

CCID

)

A/C
Compressor



Volt DC

346





Electric
Generator

Inverter/
Converter

Volt DC

346

Electric
Moto

r

120

Volt AC

Volt DC

346

0 V

Hybrid Vehicle Computer



00

Volt DC

A/C
Compressor

Electric
Generator

Inverter/





Converter

00

Electric
Moto

r

Volt DC

HV Battery
Assembl

y

00

Volt DC

00

Volt AC

0 V





Battery Charger
Assembly







S

-22-

RS Airbags & Seat Belt Pretensioners (2010 Model)

Standard Equipment

• Electronic frontal impact sensors (2) are mounted in the engine
compartment  as illustrated.

• Front seat belt pretensioners are mounted near the base of the B-pillars .

• A frontal dual stage driver airbag  is mounted in the steering wheel hub.

• A frontal twin-chamber shaped dual stage passenger airbag  is integrated

into the dashboard and deploys through the top of the dashboard.

• The SRS computer , which contains an impact sensor, is mounted on the
floor pan underneath the instrument panel, forward of the shift lever.

• Front electronic side impact sensors (2) are mounted near the base of the B­pillars. 

• Rear electronic side impact sensors (2) are mounted near the base of the C­pillars. 

• Front seat side airbags  are mounted in the front seatbacks.

• Side curtain airbags  are mounted along the outer edge inside the roof

rails.

• A driver knee airbag  is mounted on the lower portion of the dash.

• Active (mechanical non-pyrotechnic) front seat headrests (see description

on page 30).

WARNING:

The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.

Electronic Impact Sensors and Side Airbags

Standard Frontal Airbags, Seat Belt Pretensioners, Knee Airbag, Side Curtain

Airbags





















Side Curtain Airbag

Inflators











S

-23-

RS Airbags & Seat Belt Pretensioners (2010 Model -

Continued)

NOTE:
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.

The knee airbag deploy simultaneously with the frontal airbags.

The Prius Plug-in hybrid is equipped with a standard front passenger
occupant classification system that may prohibit the deployment of the
front passenger frontal airbag and seat belt pretensioners. If the passenger
occupant classification system prohibits deployment during an SRS event,
the passenger SRS will not re-arm nor deploy.

SRS System Diagram

Frontal, Knee, Front Seatback Mounted Side, Side Curtain Airbags

Driver Knee Airbag and Inflator

Front Airbag
Sensors

Knee Airbag

Passenger Frontal Airbag

Front Seat Side Airbag

Side Airbag Sensor

Front Seat Side Airbag

Driver Frontal Airbag

Front Seat Belt
Pretensioner

Side Curtain Airbag

Rear Side
Airbag Sensor

Rear Side
Airbag Sensor

Front Seat Belt
Pretensioner

Side Curtain Airbag

Side Airbag Sensor

Chock Wheels Set Parking Brake

Push P Position Switch

Canada

U.S.A.

-24-

WARNING:

• Never assume the Prius Plug-in hybrid is shut off simply because it is

silent.

• Always observe the instrument cluster for the READY indicator

status to verify whether the vehicle is on or shut off. The vehicle and
remote air conditioning system are shut off when the READY
indicator is off and the instrument cluster lights are out.

• Failure to shut off and disable the vehicle before emergency response
procedures are performed may result in serious injury or death from
the unintentional deployment of the SRS or severe burns and electric
shock from the high voltage electrical system.

Emergency Response (2010 Model)

On arrival, emergency responders should follow their standard
operating procedures for vehicle incidents. Emergencies involving the
Prius Plug-in hybrid may be handled like other automobiles except as
noted in these guidelines for Extrication, Fire, Overhaul, Recovery,
Spills, First Aid, and Submersion.

Extrication

• Immobilize Vehicle

Chock wheels and set the parking brake.
Push the P position switch to engage park (P).

-25-

Emergency Response (2010 Model - Continued)

Extrication (Continued)

• Disable Vehicle

Perform these steps first if the charge cable assembly is
connected to the vehicle.

1. Disconnect the charge cable assembly connector from the
vehicle. To disconnect it, push the orange lock release button on
the top of the connector and pull it away from the vehicle.

2. Close the charge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the
electrical outlet.

Performing either of the following two procedures will shut the
vehicle off and disable the HV battery assembly, SRS, gasoline fuel
pump, and optional remote air conditioning system.

Procedure #1

1. Confirm the status of the READY indicator in the instrument
cluster. If the READY indicator is illuminated, the vehicle is on
and operational.

2. Shut off the vehicle by pushing the power button once.

3. The vehicle is already shut off if the instrument cluster lights are
not illuminated. Do not push the power button because the
vehicle may start.

4. If the smart key is easily accessible, keep it at least 16 feet (5
meters) away from the vehicle.

5. Disconnect the 12 Volt auxiliary battery under the cover, tire

repair kit, and foam insert in the cargo area to prevent accidental
restarting of the vehicle.

Disconnect Charge Cable Connector

Close Charge Inlet Cap and Charge

Inlet Door

Disconnect Plug

Shut Off Vehicle (READY-OFF)

Remove Auxiliary Battery Cover Remove Tire Repair Kit and Foam

Insert

-26-

Emergency Response (2010 Model - Continued)

Extrication (Continued)

Procedure #2 (Alternate if power button is inaccessible)

1. Open the hood.

2. Remove the fuse box cover.

3. Remove the IGCT fuse (30A green colored) and AM2 fuse
(7.5A brown colored) in the engine compartment fuse box (refer
to illustration). If the correct fuse cannot be recognized, pull all
fuses in the fuse box.

4. Disconnect the 12 Volt auxiliary battery under the tire repair kit
and foam insert in the cargo area.

NOTE:

Before disconnecting the 12 Volt auxiliary battery, if necessary,
lower the windows, unlock the doors and open the hatch as required.
Once the 12 Volt auxiliary battery is disconnected, power controls
will not operate.

WARNING:

• The high voltage system, including the charging system, may

remain powered for up to 10 minutes after the vehicle is shut off,
disabled, or charging stops. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or
breaching any orange high voltage power cable or high voltage
component.

• The SRS may remain powered for up to 90 seconds after the vehicle

is shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS
components.

• If none of the disabling procedures can be performed, proceed with

caution as there is no assurance that the high voltage electrical
system, SRS, or fuel pump are disabled.

Remote Hood Release Hood Latch Release

Remove Fuse Box Cover

IGCT and AM2 Fuse Location in

Engine Compartment Fuse Box

Remove Battery Cover

Remove Tire Repair Kit and Foam

Insert

AM2 f

us

e (7.5A)

IGCT f

use (

30A

)

12 Volt Auxiliary Battery

-27-

Emergency Response (2010 Model - Continued)

Extrication (Continued)

•

Stabilize Vehicle

Crib at (4) points directly under the front and rear pillars.
Do not place cribbing under the high voltage power cables, exhaust
system, or fuel system.

NOTE:
The Prius Plug-in hybrid is equipped with a tire pressure warning
system that by design prevents pulling the metal valve stem with
integral transmitter from the wheel. Snapping the valve stem with
pliers or removing the valve cap and Schrader valve will release the
air in the tire.

•

Access Patients

Glass Removal

Use normal glass removal procedures as required.

SRS Awareness

Responders need to be cautious when working in close proximity
to undeployed airbags and seat belt pretensioners. Front dual
stage airbags automatically ignite both stages within a fraction of
a second.

Door Removal/Displacement

Doors can be removed by conventional rescue tools such as hand,
electric, and hydraulic tools. In certain situations, it may be
easier to pry back the vehicle body to expose and unbolt the
hinges.

Metal Valve Stem with Integral

Transmitter

Cribbing Points

Metal Valve Stem with Integral

Transmitter Installed on Wheel

CribbingPoints

-28-

Emergency Response (2010 Model - Continued)

Extrication (Continued)

Roof Removal

The Prius Plug-in hybrid is equipped with side curtain airbags.
When undeployed, total roof removal is not recommended.
Patient access through the roof can be performed by cutting the
roof center section inboard of the roof rails as illustrated. This
would avoid breaching the side curtain airbags, inflators, and
wiring harness.

NOTE:
The side curtain airbags may be identified as illustrated on this page
(additional component details on page 22).

Dash Displacement

The Prius Plug-in hybrid is equipped with side curtain airbags.
When undeployed, total roof removal is not recommended to
avoid breaching the side curtain airbags, inflators, and SRS
harnesses. As an alternative, dash displacement may be
performed by using a Modified Dash Roll.

Side, Curtain, and Knee Airbag Identifiers

Roof Removal Area

SRS CURTAIN

AIRBAG

SRS CURTAIN

AIRBAG

SRS KNEE AIRBAG

SRS SIDE AIRBAG

Removable Area

Side Curtain Airbag Inflators

Removable Area

Side Curtain Airbag Inflators

-29-

Emergency Response (2010 Model - Continued)

Extrication (Continued)

NOTE:

The Prius Plug-in hybrid has an orange power cable that is
energized during charging. The charge power cable is routed along
the driver side front fender apron member (top rail) that is
concealed by the front fender panel.

Rescue Lift Air Bags

Responders should not place cribbing or rescue lift air bags under
the high voltage power cables, exhaust system, or fuel system.

Repositioning Steering Wheel and Front Seats

Telescopic steering wheel and seat controls are shown in the
illustrations.

Charge Inlet Power Cable

Tilt and Telescoping Control

Front Seat Controls

Charge Inlet Power Cable

-30-

Emergency Response (2010 Model - Continued)

Extrication (Continued)

Active Headrest Removal

The Prius Plug-in hybrid is equipped with active headrests,
located in both front seatbacks. The active headrests are
mechanical non-pyrotechnic head supports that are designed to
reduce neck injuries in the event of a rear collision.

No special methods are required to remove the headrests. Push
the release button and lift to remove the headrest.

Front Active Headrest

Electrochromic Auto Dimming Rear View Mirror

Headrest

Upper Unit

Cable

Lower Uni

t

NOTE:

The Prius Plug-in hybrid is equipped with an optional
electrochromic auto dimming rear view mirror. The mirror
contains a minimal amount of transparent gel sealed between two
glass plates that will not normally leak.

Mirr

or Cross Sectio

n

Sealed Electrochromic Coating

-31-

Emergency Response (2010 Model - Continued)

preventing the responder from properly applying water through the
available vent openings safely. Therefore, it is recommended that the
incident commander allow the Prius Plug-in hybrid HV battery
assembly to burn itself out.

Fire

Approach and extinguish a fire using proper vehicle fire fighting practices as
recommended by NFPA, IFSTA, or the National Fire Academy (USA).

• Extinguishing Agent
Water has been proven to be a suitable extinguishing agent.

Defensive Fire Attack

If the decision has been made to fight the fire using a defensive attack,
the fire attack crew should pull back a safe distance and allow the Li­ion battery cells to burn themselves out. During this defensive
operation, fire crews may utilize a water stream or fog pattern to
protect exposures or to control the path of smoke.

• Initial Fire Attack

Perform a fast, aggressive fire attack.
Divert the runoff from entering watershed areas.
Attack teams may not be able to identify a Prius Plug-in hybrid until
the fire has been knocked down and overhaul operations have
commenced.

• Fire When Vehicle Charging

When extinguishing a fire when charging, the vehicle and charge
cable assembly may come in contact with water. As soon as possible,
shut off the power to the electrical outlet before disconnecting the
charge cable assembly. Perform the charge cable assembly
disconnection procedure contained in the Extrication section on page

25.

• Fire in the HV Battery Assembly
Should a fire occur in the Li-ion HV battery assembly, attack crews

should utilize a water stream or fog pattern to extinguish any fire
within the vehicle except

for the HV battery assembly.

When allowed to burn themselves out, the Prius Plug-in hybrid Li-ion

battery cells burn rapidly and are reduced to a combination of ashes
and metal components.

WARNING:

• Burning batteries may irritate the eyes, nose, and throat. To
prevent injury wear personal protective equipment suitable for
organic solvents including SCBA.

• The battery cells are contained within a metal case and
accessibility is limited.

• To avoid serious injury or death from severe burns or electric
shock, never breach or remove the high voltage battery assembly
cover under any circumstance including fire.

• To prevent serious injury or death, shut off the utility circuit
supplying power to the charge cable assembly before disconnecting
it if the CCID or charge cable assembly are submerged in water.

Offensive Fire Attack
Normally,

flooding a Li-ion HV battery assembly with copious

amounts of water at a safe distance will effectively control the HV
battery assembly fire by cooling the adjacent Li-ion battery cells to a
point below their ignition temperature. The remaining cells on fire, if
not extinguished by the water, will burn themselves out.

However, flooding the Prius Plug-in hybrid HV battery assembly is

not

recommended due to the battery case design and location

E

-32-

mergency Response (2010 Model - Continued)

Overhaul

During overhaul, immobilize and disable the vehicle if not already done.
Refer to illustrations starting on page 24, 25 and 26. The HV battery
assembly cover should never be breached or removed under any
circumstances including fire. Doing so may result in severe electrical burns,
shock, or electrocution.

• Immobilize Vehicle
Chock wheels and set the parking brake.
Push the P position switch to engage park (P).

• Disable Vehicle

Perform these steps first if the charge cable assembly is
connected to the vehicle.

1. Disconnect the charge cable assembly connector from the vehicle.

To disconnect it, push the orange lock release button on the top
of the connector and pull it away from the vehicle.

2. Close the recharge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the

electrical outlet.

Performing either of the following two procedures will shut the
vehicle off and disable the HV, SRS, charging and remote air
conditioning systems.

Procedure #1

1. Confirm the status of the READY indicator in the instrument

cluster. If the READY indicator is illuminated, the vehicle is on
and operational.

2. Shut off the vehicle by pushing the power button once.

3. The vehicle is already shut off if the instrument cluster lights are

not illuminated. Do not push the power button because the
vehicle may start.

4. If the smart key is easily accessible, keep it at least 16 feet (5

meters) away from the vehicle.

5. Disconnect the 12 Volt auxiliary battery under the cover and

tools in the cargo area to prevent accidental restarting of the
vehicle.

Procedure #2

1. Open the hood and remove the fuse box cover.

2. Remove the

IGCT fuse (30A green colored) and AM2 fuse

(7.5A brown colored) in the engine compartment fuse box as

illustrated on page 26. If the correct fuse cannot be recognized,
pull all fuses in the fuse box.

3. Disconnect the 12 Volt auxiliary battery under the cover in the
cargo area.

NOTE:

Before disconnecting the 12 Volt auxiliary battery, if necessary, lower
the windows, unlock the doors and open the hatch as required. Once the
12 Volt auxiliary battery is disconnected, power controls will not
operate.

WARNING:

• The high voltage system, including the charging system, may remain

powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns
or electric shock, avoid touching, cutting, or breaching any orange
high voltage power cable or high voltage component.

• The SRS may remain powered for up to 90 seconds after the vehicle is

shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.

• If none of the disabling procedures can be performed, proceed with

caution as there is no assurance that the high voltage electrical system,
SRS, fuel pump, recharging, or remote air conditioning are disabled.

Recovery of Li-ion HV Battery Assembly

For information regarding recovery of the HV battery assembly, contact:

United States: [phone]
Canada: (888) TOYOTA 8 [[phone]]

E

-33-

mergency Response (2010 Model - Continued)

Spills

The Prius Plug-in 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 acidic vapor caused by the reaction of the
electrolyte with moisture may irritate the nose and throat.

• To avoid injury by coming in contact with the electrolyte or acidic
vapor, wear personal protective equipment for organic electrolyte
including SCBA or protective mask for acidic vapors.

In an emergency, the Li-ion battery part number G9280-47160 manufacturer’s
Material Safety Data Sheet (MSDS) is available by contacting:

United States: CHEMTREC at [phone]
Canada: CANUTEC at *666 or [phone] (collect)

• 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 acid or 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 acidic vapors or SCBA.

• Absorbent
Suitable absorbent for an organic solvent.

First Aid

Emergency responders may not be familiar with Li-ion electrolyte exposure
when rendering aid to a patient. Exposure to the electrolyte is unlikely except
in a catastrophic crash or through improper handling. Utilize the following
guidelines in the event of exposure.

• Wear Personal Protective Equipment (PPE)
Splash shield or safety goggles. Fold down helmet shields are not

acceptable for acid or 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 acidic vapors or SCBA

• Absorption
Perform gross decontamination by removing affected clothing and
properly disposing of the garments.
Rinse the affected areas with water for 20 minutes.
Transport patients to the nearest emergency medical care facility.

• Inhalation in Non-Fire Situations
Contact with the acidic vapor caused by reaction of the electrolyte
with moisture may irritate the nose and throat. In severe cases such as
confined spaces, move exposed patients to a well ventilated area.
Transport patients to the nearest emergency medical care facility.

• Inhalation in Fire Situations
Toxic gases are given off as by-products of combustion. All
responders in the Hot Zone should wear the proper PPE for fire
fighting including SCBA.
Move a patient from the hazardous environment to a safe area and
administer oxygen.
Transport patients to the nearest emergency medical care facility.

Em

-34-

ergency Response (2010 Model - Continued)

First Aid (Continued)

• Ingestion
Do not induce vomiting, unless instructed by the doctor.
If vomiting occurs naturally, avoid aspiration.
Transport patients to the nearest emergency medical care facility.

Submersion

A submerged hybrid vehicle does not have high voltage potential on the metal
vehicle body, and is safe to touch.

Access Patients

Responders can access the patient and perform normal extrication
procedures. High voltage orange color coded power cables and high
voltage components should never be touched, cut, or breached.

Vehicle Recovery

If a hybrid vehicle is fully or partially submerged in water, emergency
responders may not be able to determine if the vehicle has been
automatically disabled. The Prius Plug-in hybrid may be handled by
following these recommendations:

Perform these steps first if the charge cable assembly is
connected to the vehicle (see illustrations on page 25).

1. Shut off the utility circuit supplying power to the charge cable
assembly.

2. Disconnect the charge cable assembly connector from the vehicle.
To disconnect it, push the orange lock release button on the top
of the connector and pull it away from the vehicle.

3. Close the recharge inlet cap and charge inlet door.

4. Disconnect the plug of the charge cable assembly from the
electrical outlet.

5. Remove the vehicle from the water.

6. Drain the water from the vehicle if possible.

7. Follow the immobilizing and disabling procedure starting on page
24, 25 and 26.

NOTE:

If park (P) system related components are damaged due to
submersion, it may not be possible to shift from park (P) to neutral
(N). If this is the case, make sure to tow or move the vehicle with the
front wheels off the ground.

WARNING:

To prevent serious injury or death, shut off the utility circuit supplying
power to the charge cable assembly before disconnecting it if the
CCID or charge cable assembly are submerged in water.

-35-

Roadside Assistance (2010 Model)

The Prius Plug-in hybrid utilizes an electronic shift selector and a P
position switch for selecting park (P). If the 12 Volt auxiliary battery is
discharged or disconnected, the vehicle cannot be started nor can it be
shifted out of park (P). If discharged, the 12 Volt auxiliary battery can
be jump started to allow vehicle starting and shifting out of park (P).
Most other roadside assistance operations may be handled like
conventional Toyota vehicles.

Roadside assistance is available in the United States by contacting
[phone]

Towing

The Prius Plug-in hybrid is a front wheel drive vehicle and it must be towed
with the front wheels off the ground. Failure to do so may cause serious
damage to Hybrid Synergy Drive components.

• A flat bed trailer is the preferred method of towing.

• The vehicle may be shifted out of park (P) into neutral (N) when in either

the ignition-on or READY-on mode. To select neutral (N), it is necessary
to hold the shift selector in the N position for approximately 0.5 seconds.

• If the 12 Volt auxiliary battery is discharged, the vehicle will not start and
shifting out of park (P) is not possible. There is no manual override
except to jump start the vehicle, refer to the Jump Starting on page 38.

• If a tow truck is not available, in an emergency the vehicle may be towed
using a cable or chain secured to the emergency towing eyelet or rear tow
hook for short distances at low speeds (below 18 mph (30km/h)). The
eyelet is located with the tools under the driver seat of the vehicle, refer to
the illustration on page 37.

Starting Vehicle Move Shift Selector to N Position

Towing Eyelet Mounting Location Eyelet Installation

Rear Hook Location

Rear Hoo

k

-36-

Roadside Assistance (2010 Model - Continued)

Electric Hatch Opener Switch

Manual Hatch Release

Electric Fuel Door Opener Switch Manual Fuel Door Release

Electric Hatch Opener

The Prius Plug-in hybrid is equipped with an electric hatch opener. In the
event of 12 Volt power loss, the hatch cannot be opened from the outside of
the vehicle.

The electric hatch can be opened manually using the release as shown in the
illustration.

Hatch Opener Switch

Back Hatch, Viewed
from Inside Vehicle

Electric Fuel Door Opener

The Prius Plug-in hybrid is equipped with an electric fuel door opener. In the
event of 12 Volt power loss, the fuel door can only be opened using the
manual release located inside the cargo area.

-37-

Roadside Assistance (2010 Model - Continued)

Emergency Tire Puncture Repair Kit

Tools, Jack and Towing Eyelet under Driver Seat

Emergency Tire Puncture Repair Kit in Cargo Area

The Prius Plug-in hybrid does not contain a spare tire. Instead, an emergency
tire puncture repair kit is provided along with the jack, tools, and towing
eyelet. These items are located as shown in the illustration.

Towing Eyelet, Jack
and Tools

Emergency Tire
Puncture Repair Kit

Remote Hood Release Hood Latch Release

Remove Fuse Box Cover Open Positive Terminal Cover

Jumper Cable Connections

Positive Terminal

Ground

R

-38-

oadside Assistance (2010 Model - Continued)

Jump Starting

The 12 Volt auxiliary battery may be jump started if the vehicle does not start
and the instrument cluster gauges are dim or off after depressing the brake
pedal and pushing the power button.

The 12 Volt auxiliary battery is located in the cargo area. If the 12 Volt
auxiliary battery is discharged, the rear hatch cannot be opened. Instead, the
vehicle can be jump started by accessing the remote positive 12 Volt auxiliary
battery terminal in the engine compartment fuse box.

• Open the hood, remove the fuse box cover, and open the positive terminal
cover.

• Connect the positive jumper cable to the positive terminal.

• Connect the negative jumper cable to a solid ground.

• Place the smart key in proximity to the interior of the vehicle, depress the

brake pedal, and push the power button.

NOTE:
If the vehicle does not recognize the smart key after connecting the
booster battery to the vehicle, open and close the driver door when the
vehicle is shut off.

If the smart key internal battery is dead, touch the Toyota emblem side of
the smart key to the power button during the start sequence. See the
instructions and illustrations on page 10 for more details.

• The high voltage HV battery assembly cannot be jump started.

Immobilizer

The Prius Plug-in hybrid is equipped with a standard immobilizer system.

• The vehicle can be started only with a registered smart key.

About the Prius Plug-in Hybrid (2012 Model)

The Prius Plug-in hybrid contains a gasoline engine, an electric motor,
and a newly developed large capacity Li-ion battery. It is the first
Toyota hybrid that allows the HV battery to be plugged-in and charged
by an external power source. Two power sources are stored on board
the vehicle:

When the HV battery is discharged the vehicle operates in Hybrid Vehicle
mode

3. Gasoline stored in the fuel tank for the gasoline engine.

4. Electricity stored in a large capacity externally chargeable high
voltage Hybrid Vehicle (HV) battery assembly for the electric
motor.

HV (Hybrid Vehicle) Mode:

 During light acceleration at low speeds, the vehicle is powered by

the electric motor. The gasoline engine is shut off.

Depending on the driving conditions, one or both sources are used to
power the vehicle. The following illustration demonstrates how the
Prius Plug-in hybrid operates in various driving modes.



During normal driving, the vehicle is powered mainly by the
gasoline engine. The gasoline engine also powers the generator to
recharge the HV battery assembly and to drive the motor.

Plug-in EV (Electric Vehicle) Mode:



During full acceleration, such as climbing a hill, both the gasoline
engine and the electric motor power the vehicle.

 Utilizing the charge cable assembly connected to a 120 Volt outlet,

the vehicle’s HV battery can be charged within 3 hours.



During deceleration, such as when braking, the vehicle regenerates
the kinetic energy from the front wheels to produce electricity that
recharges the HV battery assembly.



When the HV battery is sufficiently charged, the vehicle will
basically run on the power of the electric motor for approximately
11 miles.



While the vehicle is stopped, the gasoline engine and electric motor
are off, however the vehicle remains on and operational.



If the vehicle exceeds approximately 60 mph (100 km/h) or
accelerates suddenly when traveling in EV mode, the gasoline
engine and electric motor work together to power the vehicle.

 Normal Driving

-

39-

Plug-in charging

Electricity Electricity and gasoline Electricity and gasoline Electricity

Electricity and gasoline
(Additional electricity
extracted from batteries)

Charging batteries

Engine automatically stopped

 Hard Acceleration

 Starting  Normal Driving  Acceleration  Deceleration

Exceeds
Approximately 60 mph (100 km/h)

 Stopping

EV Mode HV (Hybrid Vehicle) Mode

 Plug-in Charging

Prius Plug-in Hybrid Identification (2012 Model) Prius Plug-in Hybrid Identification (2012 Model)

-40-

In appearance, the 2012 model year Prius Plug-in hybrid is a 5-door
hatchback. Exterior, interior, and engine compartment illustrations are
provided to assist in identification.

In appearance, the 2012 model year Prius Plug-in hybrid is a 5-door
hatchback. 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 and on the driver door pillar.

The alphanumeric 17 character Vehicle Identification Number (VIN) is
provided in the front windshield cowl and on the driver door pillar.

Example VIN: JTDKN3DPExample VIN: JTDKN3DPA82020211

A Prius Plug-in hybrid is identified by the first 8 alphanumeric characters
JTDKN3DP.

Driver Side Windshield and Driver Side B Pillar

Exterior

 and logos on the hatch.
 logo on the each front fender.
 Charge inlet door located on the passenger side rear quarter panel.
 Gasoline fuel filler door located on the driver side rear quarter panel.

Exterior Driver Side View

Exterior Front and Rear View

Exterior Rear and Passenger Side View

















Prius Plug-in Hybrid Identification (2012 Model ­Continued)

Prius Plug-in Hybrid Identification (2012 Model ­Continued)

-41-

InteriorInterior

Interior View

Instrument Cluster View

 An instrument cluster (speedometer, READY light, shift position indicators,

warning lights) located in center of the dash and near the base of the
windshield.



 logo located on the passenger side of the dash.





Prius Plug-in Hybrid Identification (2012 Model)
(Continued)

Prius Plug-in Hybrid Identification (2012 Model)
(Continued)

-42-

Engine CompartmentEngine Compartment

Engine Compartment View





1.8-liter aluminum alloy gasoline engine.

 Logo on the plastic engine cover.



Hybrid Synergy Drive Component Locations &
Descriptions (2012 Model)

Hybrid Synergy Drive Component Locations &
Descriptions (2012 Model)

-43-

Component Location Description

12 Volt 
Auxiliary Battery

Passenger Side
of Cargo Area

A lead-acid battery that supplies power to the

low voltage devices.
Hybrid  Vehicle
(HV) Battery
Assembly

Cargo Area 207.2 Volt Lithium-ion (Li-ion) battery pack

consisting of 3.7 Volt cells connected in a

series circuit.
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 motor. The

inverter/converter also converts AC

electricity from the electric generator and

electric motor (regenerative braking) to DC

that charges the HV battery assembly.
Gasoline 
Engine

Engine
Compartment

Provides two functions:

1) Powers vehicle.

2) Powers generator to charge 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 electric 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 charges the

HV battery assembly.
A/C Compressor
(with Inverter) 

Engine
Compartment

3-phase high voltage AC electrically driven

motor compressor.

Hybrid Synergy Drive Components















Components (Top View) and High Voltage Power Cables
















Hybrid Synergy Drive Component Locations &
Descriptions (2012 Model - Continued)

Hybrid Synergy Drive Component Locations &
Descriptions (2012 Model - Continued)

-44-

Component Location Description

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.

Fuel Tank and Fuel Line



Hybrid Synergy Drive Component Locations &
Descriptions (2012 Model - Continued)

Hybrid Synergy Drive Component Locations &
Descriptions (2012 Model - Continued)

Key Specifications:Key Specifications:

-45-

Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine

Electric Motor: 80 hp (60 kW), AC Motor

Transmission: Automatic Only (electrically controlled

continuously variable transaxle)

HV Battery Assembly: 207.2 Volt Sealed Li-ion Battery

Curb Weight: 3,186 lbs/1,445 kg

Fuel Tank: 10.6 gals/40.0 liters

Frame Material: Steel Unibody

Body Material: Steel Panels except for Aluminum Hood and

Hatch

Seating Capacity: 5 passenger

Steel Unibody

Aluminum Hood

Aluminum Hatch

P

-46-

lug-in Charging System Component Locations &

Descriptions (2012 Model)

Component Location Description

Charge Inlet  Passenger Side

Rear Quarter
Panel

Connects to the charge cable assembly

charge connector. Supplies the electrical

power from an external power source to the

vehicle.

Power Cable
for Charging


Passenger Side
Behind Rear
Quarter Panel

Power cable connecting the charge inlet and

charger assembly.

Charger
Assembly 

Under Hybrid
Vehicle Battery
Assembly

Boosts the AC power supplied from an

external power source and converts it to DC

to charge the HV battery assembly and

operate the A/C compressor.

Charge Cable
Assembly 

Passenger Side
Rear Quarter
Panel

Connects to the charge inlet and supplies

power from an external power source to the

vehicle.

Charge
Indicator 

Charge Inlet Illuminates, flashes, or goes off to indicate

the plug-in charging status. Also illuminates

to indicate the operation of the remote air

conditioning system.

Battery
Charger
Controller 

Under HV
Battery Assembly

Controls the HV battery assembly and

recharges it. During charging, the charge

indicator is illuminated.

Plug-in Charging System Components

Components (Top View) and Charge Inlet Power Cables















S

-47-

mart Key System (2012 Model)

The Prius Plug-in hybrid smart key system consists of a smart key
transceiver that communicates bi-directionally, enabling the vehicle to
recognize the smart key in proximity to the vehicle. Once recognized,
the smart key will allow the user to lock and unlock the doors without
pushing smart key buttons, and start the vehicle without inserting it into
an ignition switch.

Smart key features:

•

Passive (remote) function to lock/unlock the doors and start the
vehicle.

•

Wireless transmitter buttons to lock/unlock all 5 doors.

•

Hidden metal cut key to lock/unlock the doors.

Door (Lock/Unlock)

There are several methods available to lock/unlock the doors.

• Pushing the smart key lock button will lock all doors including the hatch.
Pushing the smart key unlock button once unlocks the driver door, twice
unlocks all doors.

• Touching the sensor on the backside of the driver door exterior handle, with
the smart key in proximity to the vehicle, unlocks the driver door.
Touching the sensor on the backside of the front passenger door exterior
handle, with the smart key in proximity to the vehicle, unlocks all doors.
Touching the lock sensor on either front door, or the lock button for the
hatch will lock all doors.

• Inserting the hidden metal cut key in the driver door lock and turning
clockwise once unlocks the driver door, twice unlocks all doors. To lock
all doors turn the key counter clockwise once. Only the driver door
contains an exterior door lock for the metal cut key.

Smart Key (Fob) Hidden Metal Cut Key for Door Lock

Driver Door Unlock Touch Sensor and

Lock Touch Sensor

Front Driver Door Lock

Hatch Lock Button

Release Button

Unlock Touch Sensor

Use the Hidden Metal Cut Key

Lock Touch Sensor

-48-

Smart Key System (2012 Model - Continued)

Vehicle Starting/Stopping

The smart key has replaced the conventional metal cut key, and the power
button with an integral status indicator light has replaced the ignition switch.
The smart key only needs to be in proximity to the vehicle to allow the system
to function.

• With the brake pedal released, the first push of the power button operates
the accessory mode, the second push operates the ignition-on mode, and the
third push turns the ignition off again.

Ignition Mode Sequence (brake pedal released):

• Starting the vehicle takes priority over all other ignition modes and is
accomplished by depressing the brake pedal and pushing the power button
once. To verify the vehicle has started, check that the power button status
indicator light is off and the READY light is illuminated in the instrument
cluster.

• If the internal smart key battery is dead, use the following method to start
the vehicle.

1. Touch the Toyota emblem side of the smart key to the power button.

2. Within the 5 seconds after the buzzer sounds, push the power button

with the brake pedal depressed (the READY light will illuminate).

• Once the vehicle has started and is on and operational (READY-ON), the
vehicle is shut off by bringing the vehicle to a complete stop and then
depressing the power button once.

• To shut off the vehicle before coming to a stop in an emergency, push and
hold down the power button for more than 3 seconds. This procedure may
be useful such as at an accident scene in which the READY indicator is on
and the drive wheels remain in motion.

Ignition Mode

Power Button Indicator Light

Off Off

Accessory Amber

Ignition-On Amber

Brake Pedal Depressed Green

Vehicle Started (READY-ON) Off

Malfunction Blinking Amber

Power Button with Integral Status

Indicator Light

Ignition Modes (Brake Pedal Released)

Starting Sequence

(Brake Pedal Depressed)

Smart Key Recognition

(When Smart Key Battery is Dead)

Accessory

Ignition-On

Vehicle Of

f

Button Push

Button Push

Button Push

-49-

Electronic Shift Selector (2012 Model)

The Prius Plug-in hybrid electronic shift selector is a momentary select
shift-by-wire system that can be used to select reverse (R), neutral (N),
drive (D), or engine brake (B) states.

• These states may only be selected while the vehicle is on and operational
(READY-on), except for neutral (N) which may also be selected while in
the ignition-on mode. After R, N, D, or B is selected, the transaxle remains
in that state, identified on the instrument cluster, but the shift selector
returns to the home position. To select neutral (N), it is necessary to hold
the shift selector in the N position for approximately 0.5 seconds.

• Unlike a conventional vehicle, the electronic shift selector does not contain
a park (P) position. Instead, a separate P position switch located above the
shift selector selects park (P).

• When the vehicle is stopped, regardless of shift state, the electro­mechanical parking lock pawl is engaged to lock the transaxle into park (P)
by either pressing the P position switch or pressing the power button to shut
off the vehicle.

• Being electronic, the shift selector and park (P) systems depend on the low
voltage 12 Volt auxiliary battery for power. If the 12 Volt auxiliary battery
is discharged or disconnected, the vehicle cannot be started and cannot be
shifted into or out of park (P). There is no manual override except to
reconnect the auxiliary battery or jump start the vehicle, refer to Jump
Starting on page 75.

Electronic Shift Selector and P Position Switch

Home Position

Instrument Cluster Shift State Indicator

Indicates
Selected State

H

-50-

ybrid Synergy Drive Operation (2012 Model)

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 lit, 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 Plug-in hybrid, 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 and instrument cluster lights are off.

• The vehicle may be powered by:

1. The electric motor only.

2. A combination of both the electric motor and the gasoline engine.

• The vehicle computer determines the mode in which the vehicle operates in
order to improve fuel economy and reduce emissions. The Prius Plug-in
hybrid features EV (Electric Vehicle) mode, a mode that is automatically
selected when the HV battery is charged using an external power source.
Power and ECO (Economy) modes are driver selectable.

1. EV Mode: When activated, and certain conditions have been met,
the vehicle operates with the electric motor powered by the HV
battery.

2. ECO Mode: When activated, this mode helps enhance fuel
economy on trips that involve frequent braking and acceleration.

3. Power Mode: Optimizes acceleration feel by increasing the power
output more quickly at the beginning of accelerator pedal
operation.

Instrument Cluster READY Indicator

Economy Drive Mode Switch/Power Mode Switch

Vehicle Proximity Notification System

Vehicle Proximity Notification System
A new feature on the Prius Plug-in hybrid is the vehicle proximity notification
system that emits a sound when the vehicle is driven using only the electric
motor at speeds less than 15 mph. The sound is intended to notify pedestrians
that the vehicle is approaching.

H

-51-

ybrid Vehicle (HV) Battery Assembly (2012 Model)

The Prius Plug-in hybrid features a large capacity high voltage Hybrid
Vehicle (HV) battery assembly that contains newly developed 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 lower part of the cargo area behind the rear seat. The metal case is
isolated from high voltage and concealed by a carpeted panel in the cabin
area.

• The HV battery assembly consists of 3.7 Volt Li-ion battery cells connected
in series-parallel circuit to produce approximately 207.2 Volts. Each Li-ion
battery cell is non-spillable and contained in a sealed metal 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.

Components Powered by the HV Battery Assembly

HV Battery Assembly Recovery

• If recovery of the HV battery assembly is necessary, please contact:

United States: [phone]
Canada: (888) TOYOTA 8 [[phone]]

HV Battery Assembly

HV Battery Assembly

Battery assembly voltage

207.2 V

Number of Li-ion battery cells in the battery

56 cells

Li-ion battery cell voltage

3.7 V

Li-ion battery cell dimensions

4.13 x 5.83 x 1.04 in.
(105 x 148 x 27 mm)

Li-ion cell weight

1.60 lbs (726 g)

Li-ion battery assembly dimensions

29.4 x 37.3 x 6.9 in.

(747 x 948 x 176 mm)

Li-ion battery assembly weight

168 lbs (76 kg)

•

Electric Motor

•

Inverter/Converter

• Power Cables • A/C Compressor

• Electric Generator

Pl

-52-

ug-in Charging System (2012 Model)

The plug-in charging system uses an on-board charger to convert AC power
supplied via the charge cable assembly to DC power that can be used to charge
the HV battery assembly. The charging system uses refined charging control to
ensure battery durability and prevent fires due to overcharging.

The utility power supplied by the charge cable assembly is converted by the
onboard charger assembly to the approximately 207.2 Volts DC used to charge
the HV battery assembly.

Prius Plug-in hybrid vehicles for North America are supplied with a charge
cable assembly designed to allow charging from a 120 Volt AC NEMA 5-15R
receptacle. The maximum current flow during charging is 12 A.

NOTE:
The Prius Plug-in hybrid is compatible with aftermarket chargers or Electric
Vehicle Supply Equipment (EVSE), which is compliant with SAE J1772,
available from different manufacturers other than Toyota. Some EVSE’s are
available with 240 Volt input for quicker charging.

Safety Concerns
Since the operation of the plug-in charging system allows high voltage
electrical flow when the vehicle is shut off, it is important to recognize how the
system is activated, deactivated, and disabled.

System Activation:
The following steps provide a simplified explanation on how to charge the
vehicle.

1. Confirm that the vehicle is off and in park (P).

2. Connect the charge cable assembly to a suitable 120 Volt wall
receptacle.

3. Confirm the presence of power, and test the CCID (Charging Circuit
Interrupter Device).

4. Connect the charge cable assembly to the vehicle charge inlet
connector.

5. Confirm that the vehicle’s charge indicator illuminates.

When charging, the high voltage cables are energized. Utility electricity flows
from the charge inlet, its voltage is then boosted and it is provided to the HV
battery assembly and air conditioning compressor. Charging normally
completes within 3 hours and will stop automatically.

Charge Cable Assembly and Charge

Indicator

POWER Indicator, TEST Button and

RESET Button

Plug-in Charging System Operation (READY Indicator Off)

Charge Indicator

AC Flow

Charge Inlet

(Inlet to Charger )

HV Battery Assembly

Battery Charger Assembly

-53-

Plug-in Charging System (2012 Model - Continued)

System Deactivation:
The following steps explain how to stop charging.

1. Disconnect the charge cable assembly connector from the vehicle.
To disconnect it, push the lock release button on the top of the
connector and pull it away from the vehicle.

2. Close the charge inlet door.

3. Disconnect the plug of the charge cable assembly from the
electrical outlet.

Disconnect Charge Cable Connector Close Charge Inlet Door

Disconnect Plug

Remove Deck Board and Auxiliary

Box

12 V Auxiliary Battery

Push

When the charging system is deactivated, high voltage cables are de­energized and the high voltage electrical flow stops in the charge cable
assembly and vehicle.

WARNING:

The high voltage system, including the charging system, may remain
powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns or
electric shock, avoid touching, cutting, or breaching any orange high
voltage power cable or high voltage component.

System Disabling:
To disable the charging system, disconnect the 12 Volt auxiliary battery
after performing the above deactivation procedure.

12 Volt Auxiliary Battery

-54-

Remote Air Conditioning Systems (2012 Model)

System Disabling:

Remote Air Conditioning System

To disable the remote air conditioning system, first shut off the vehicle by
pushing the power button if necessary and ensuring that the READY indicator
and instrument cluster lights are off. Second, disconnect the 12 Volt auxiliary
battery. After performing these two steps, the remote air conditioning system
will be disabled and will not activate even if the smart key A/C button is pushed.

The remote air conditioning system is similar to a remote engine start system
used in a conventional gasoline vehicle to precondition the vehicle interior
while the vehicle is parked. Unlike a conventional gasoline vehicle, the Prius
Plug-in hybrid does not start the gasoline engine. Instead it utilizes the energy
stored in the High Voltage HV battery pack to operate the high voltage air
conditioning compressor to cool the vehicle interior. The system is activated
remotely by pushing the smart key A/C button and will operate for up to 10
minutes when certain conditions are met.

Safety Concerns
Since the operation of the remote air conditioning system allows high voltage
electrical flow, it is important to recognize how the system is activated,
deactivated, and disabled.

System Activation:
When the remote air conditioning system is activated, high voltage cables are
energized and high voltage electricity flows from the HV battery pack to the air
conditioning compressor. The system is operating when all of the following
conditions occur:

• All doors are closed.

• The instrument cluster lights are on, but the READY indicator light is

off.

• Air is flowing from the interior vehicle vents, and the blower fan noise
may be heard.

System Deactivation:
When the system is deactivated, the high voltage cables are de-energized and
high voltage electrical flow stops from the HV battery pack. The system is
deactivated when any one of the following conditions occur:

• After about 10 minutes of operation.

• When the HV battery pack charge level is low.

• When a door is opened, the hood is opened, or the brake pedal is

depressed.

• When the smart key A/C button is pushed twice within 3 seconds.

• When conditions for operation are not met.

Optional Remote Air Conditioning System A/C Button

Remote Air Conditioning System Operation (READY Indicator Off)

Air Conditioning

Compressor

High Voltage Flow

HV Battery

12 Volt Auxiliary

Battery

A/C Button

-55-

Low Voltage Battery (2012 Model)

Auxiliary Battery

• The Prius Plug-in hybrid contains a sealed lead-acid 12 Volt battery. The
12 Volt auxiliary battery powers the vehicle’s electrical system similar to a
conventional vehicle. As with conventional vehicles, the negative terminal
of 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 a fabric
cover, tire repair kit, and foam insert on the passenger side in the rear
quarter panel well.

NOTE:
An under hood label shows the location of the HV battery assembly
(traction battery) and 12 Volt auxiliary battery.

Remove Deck Board and Auxiliary Box 12 V Auxiliary Battery

Battery Location Label

12 Volt Auxiliary Battery

H

-56-

igh Voltage Safety (2012 Model)

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 HV battery assembly, under the vehicle floor pan, to the
inverter/converter. The inverter/converter contains a circuit that boosts the HV
battery voltage from 207.2 to 650 Volts DC. The inverter/converter creates 3­phase AC to power the motor. 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

• High voltage fuses  provide 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 and not charging, the relays stop electrical flow from
leaving the HV battery assembly.

WARNING:

The high voltage system, including the charging system, may remain
powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns
or electric shock, avoid touching, cutting, or breaching any orange
high voltage power cable or high voltage component.

• Both positive and negative power cables  are insulated from the metal
body. High voltage electricity flows through these cables and not through
the metal vehicle body. The metal vehicle body is safe to touch because it
is insulated from the high voltage components.

• 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 master warning

light

in the instrument cluster and indicate “Check Hybrid System” on

the multi-information display.

High Voltage Safety System – Vehicle Shut Off (READY-OFF)

High Voltage Safety System – Vehicle On and Operational (READY-ON)

12 Volt Auxiliary
Battery

Hybrid Vehicle
Computer

Volt DC



00

Volt DC

00



Volt AC

A/C
Compressor









Electric
Generator

Electric
Motor

00

Volt DC

00

Inverter/
Converter

Battery Charger
Assembly

AC
3-Phase

HV Battery
Assembly

12 Volt Auxiliary
Battery

Hybrid Vehicle
Compute

r

HV Battery
Assembly

Volt DC

207.2

207.2

Volt DC

Volt AC

A/C
Compressor

Volt DC

00

00

Electric
Generator

Inverter/
Converter

Electric
Moto

r

Battery Charger
Assembly

AC
3-Phase

Plug-in Charging Safety (2012 Model)

The HV battery assembly can be charged using power from an external power
outlet. AC power is supplied to the charge inlet by the charge cable assembly
and sent to the charger assembly. There are basically 2 circuits in the charger
assembly: One is an AC/DC converter circuit and the other is a booster circuit
used to boost the charger input voltage to 207.2 Volts. DC power from the
charger assembly is used to charge the HV battery assembly. To provide
information about the charging status, the battery charger controller illuminates
the charge indicator in the charge inlet during charging.

The following systems are intended to help keep vehicle occupants and
emergency responders safe from high voltage electricity:

Plug-in Charging System Safety System

• The battery charger controller monitors the charging system based on
information from various sensors. If the hybrid vehicle computer detects a
malfunction, charging is stopped, relays are opened, and the charge
indicator flashes to indicate the presence of the malfunction.

WARNING:

The high voltage system, including the charging system, may remain
powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns or
electric shock, avoid touching, cutting, or breaching any orange high
voltage power cable or high voltage component.

-57-

P

-58-

lug-in Charging Safety (2012 Model - Continued)

• The AC cables  are connected to the charger assembly. The high voltage
DC power cables from the charger assembly  are connected to the HV
battery assembly and are controlled by 12 Volt normally open charge relays
, HV system main relays  and AC leakage cut relays . When
charging is not being performed, or the remote air conditioning system is
not operating, the charge relays  and HV system main relays  electrical
flow from the HV battery assembly to the charger assembly, and the relays
in the CCID (Charging Circuit Interrupter Device)  stop the supply of
household power to the vehicle.

• Both the high voltage power cables  and the AC cables 

are insulated

from the metal body. High voltage electricity flows through these cables
and not through the metal vehicle body. The metal vehicle body is safe to
touch because it is insulated from the high voltage components.

• Ground fault monitors  and  continuously monitor for high voltage
leakage to the metal chassis while the vehicle is charging. If a malfunction

is detected, the CCID will illuminate its error light

.

• The CCID contains a power light, an error light

, a TEST button, and a
reset button. When the charge cable assembly is connected to a 120 Volt
outlet, the power light illuminates. The TEST and RESET buttons function
like a conventional residential GFCI (Ground Fault Circuit Interrupter).
Pushing the TEST button opens the CCID relays, and pushing the RESET
button resets the circuit.

Plug-in Charging System – Charging

Plug-in Charging System – Charge Completed or Malfunctioning

Charging Circuit Interrupter Device (CCID)









12V Auxiliary
Battery

Hybrid Vehicle Computer

Volt DC



207.2

Volt DC

207.2











Battery Charger
Assembly

HV Battery
Assembl

y

HV Battery
Assembl

y

Charging Circuit Interrupter Device (CCID)

A/C
Compressor



Volt DC

Inverter/
Converter

Electric
Generator

0 V

Electric
Moto

r

207.2

120

Volt AC

Hybrid Vehicle Computer











12V Auxiliary
Battery



00

00

Volt DC

00

Volt DC









Battery Charger
Assembly

A/C
Compressor

Inverter/
Converter

0 V

Electric
Generator

Electric
Moto

r

00

Volt AC

Volt DC

S

-59-

RS Airbags & Seat Belt Pretensioners (2012 Model)

Standard Equipment

• Electronic frontal impact sensors (2) are mounted in the engine
compartment  as illustrated.

• Front seat belt pretensioners are mounted near the base of the B-pillars .

• A frontal dual stage driver airbag  is mounted in the steering wheel hub.

• A frontal twin-chamber shaped dual stage passenger airbag  is integrated

into the dashboard and deploys through the top of the dashboard.

• The SRS computer , which contains an impact sensor, is mounted on the
floor pan underneath the instrument panel, forward of the shift lever.

• Front electronic side impact sensors (2) are mounted near the base of the B­pillars. 

• Rear electronic side impact sensors (2) are mounted near the base of the C­pillars. 

• Front seat side airbags  are mounted in the front seatbacks.

• Side curtain airbags  are mounted along the outer edge inside the roof

rails.

• A driver knee airbag  is mounted on the lower portion of the dash.

• Active (mechanical non-pyrotechnic) front seat headrests (see description

on page 67).

WARNING:

The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.

Electronic Impact Sensors and Side Airbags

Standard Frontal Airbags, Seat Belt Pretensioners, Knee Airbag, Side Curtain

Airbags





















Side Curtain Airbag

Inflators











S

-60-

RS Airbags & Seat Belt Pretensioners (2012 Model -

Continued)

NOTE:
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.

The knee airbag deploy simultaneously with the frontal airbags.

The Prius Plug-in hybrid is equipped with a standard front passenger
occupant classification system that may prohibit the deployment of the
front passenger frontal airbag and seat belt pretensioners. If the passenger
occupant classification system prohibits deployment during an SRS event,
the passenger SRS will not re-arm nor deploy.

SRS System Diagram

Frontal, Knee, Front Seatback Mounted Side, Side Curtain Airbags

Driver Knee Airbag and Inflator

Front Seat Belt
Pretensioner

Side Curtain Airbag

Front Seat Side Airbag

Side Airbag Sensor

Front Airbag
Sensors

Knee Airbag

Passenger Frontal Airbag

Front Seat Side Airbag

Driver Frontal Airbag

Rear Side
Airbag Sensor

Rear Side
Airbag Sensor

Front Seat Belt
Pretensioner

Side Curtain Airbag

Side Airbag Sensor

Chock Wheels Set Parking Brake

Push P Position Switch

Canada

U.S.A.

E

-61-

mergency Response (2012 Model)

WARNING:

• Never assume the Prius Plug-in hybrid is shut off simply because it is

silent.

• Always observe the instrument cluster for the READY indicator

status to verify whether the vehicle is on or shut off. The vehicle and
remote air conditioning system are shut off when the READY
indicator is off and the instrument cluster lights are out.

• Failure to shut off and disable the vehicle before emergency response
procedures are performed may result in serious injury or death from
the unintentional deployment of the SRS or severe burns and electric
shock from the high voltage electrical system.

On arrival, emergency responders should follow their standard
operating procedures for vehicle incidents. Emergencies involving the
Prius Plug-in hybrid may be handled like other automobiles except as
noted in these guidelines for Extrication, Fire, Overhaul, Recovery,
Spills, First Aid, and Submersion.

Extrication

• Immobilize Vehicle

Chock wheels and set the parking brake.
Push the P position switch to engage park (P).

-62-

Emergency Response (2012 Model - Continued)

Extrication (Continued)

• Disable Vehicle

Perform these steps first if the charge cable assembly is
connected to the vehicle.

1. Disconnect the charge cable assembly connector from the
vehicle. To disconnect it, push the lock release button on the top
of the connector and pull it away from the vehicle.

2. Close the charge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the
electrical outlet.

Performing either of the following two procedures will shut the
vehicle off and disable the HV battery assembly, SRS, gasoline fuel
pump, and optional remote air conditioning system.

Procedure #1

1. Confirm the status of the READY indicator in the instrument
cluster. If the READY indicator is illuminated, the vehicle is on
and operational.

2. Shut off the vehicle by pushing the power button once.

3. The vehicle is already shut off if the instrument cluster lights are
not illuminated. Do not push the power button because the
vehicle may start.

4. If the smart key is easily accessible, keep it at least 16 feet (5
meters) away from the vehicle.

5. Disconnect the 12 Volt auxiliary battery under the deck board

and auxiliary box in the cargo area to prevent accidental
restarting of the vehicle.

Disconnect Charge Cable Connector Close Charge Inlet Door

Disconnect Plug

Shut Off Vehicle (READY-OFF)

Remove Deck Board and Auxiliary Box

12 V Auxiliary Battery

-63-

Emergency Response (2012 Model - Continued)

Extrication (Continued)

Procedure #2 (Alternate if power button is inaccessible)

1. Open the hood.

2. Remove the fuse box cover.

3. Remove the IG2 fuse (20A yellow colored) in the engine
compartment fuse box (refer to illustration). If the correct fuse
cannot be recognized, pull all fuses in the fuse box.

4. Disconnect the 12 Volt auxiliary battery under the deck board
and auxiliary box in the cargo area to prevent accidental
restarting of the vehicle.

NOTE:

Before disconnecting the 12 Volt auxiliary battery, if necessary,
lower the windows, unlock the doors, optional power seat and open
the hatch as required. Once the 12 Volt auxiliary battery is
disconnected, power controls will not operate.

WARNING:

• The high voltage system, including the charging system, may

remain powered for up to 10 minutes after the vehicle is shut off,
disabled, or charging stops. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or
breaching any orange high voltage power cable or high voltage
component.

• The SRS may remain powered for up to 90 seconds after the vehicle

is shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS
components.

• If none of the disabling procedures can be performed, proceed with

caution as there is no assurance that the high voltage electrical
system, SRS, or fuel pump are disabled.

Remote Hood Release Hood Latch Release

Remove Fuse Box Cover

IG2 Fuse Location in Engine

Compartment Fuse Box

Remove Deck Board and Auxiliary Box 12 V Auxiliary Battery

I

G

2 f

use (

20A

)

12 Volt Auxiliary Battery

-64-

Emergency Response (2012 Model - Continued)

Extrication (Continued)

•

Stabilize Vehicle

Crib at (4) points directly under the front and rear pillars.
Do not place cribbing under the high voltage power cables, exhaust
system, or fuel system.

NOTE:
The Prius Plug-in hybrid is equipped with a tire pressure warning
system that by design prevents pulling the metal valve stem with
integral transmitter from the wheel. Snapping the valve stem with
pliers or removing the valve cap and Schrader valve will release the
air in the tire.

•

Access Patients

Glass Removal

Use normal glass removal procedures as required.

SRS Awareness

Responders need to be cautious when working in close proximity
to undeployed airbags and seat belt pretensioners.

Door Removal/Displacement

Doors can be removed by conventional rescue tools such as hand,
electric, and hydraulic tools. In certain situations, it may be
easier to pry back the vehicle body to expose and unbolt the
hinges.

Metal Valve Stem with Integral

Transmitter

Cribbing Points

Metal Valve Stem with Integral

Transmitter Installed on Wheel

CribbingPoints

-65-

Emergency Response (2012 Model - Continued)

Extrication (Continued)

Roof Removal

The Prius Plug-in hybrid is equipped with side curtain airbags.
When undeployed, total roof removal is not recommended.
Patient access through the roof can be performed by cutting the
roof center section inboard of the roof rails as illustrated. This
would avoid breaching the side curtain airbags, inflators, and
wiring harness.

NOTE:
The side curtain airbags may be identified as illustrated on this page
(additional component details on page 59).

Dash Displacement

The Prius Plug-in hybrid is equipped with side curtain airbags.
When undeployed, total roof removal is not recommended to
avoid breaching the side curtain airbags, inflators, and SRS
harnesses. As an alternative, dash displacement may be
performed by using a Modified Dash Roll.

Side, Curtain, and Knee Airbag Identifiers

Roof Removal Area

SRS CURTAIN

AIRBAG

SRS KNEE AIRBAG

SRS CURTAIN

AIRBAG

SRS SIDE AIRBAG

Removable Area

Side Curtain Airbag Inflators

Removable Area

Side Curtain Airbag Inflators

-66-

Emergency Response (2012 Model - Continued)

Extrication (Continued)

NOTE:

The Prius Plug-in hybrid has an orange power cable that is
energized during charging. The charge power cable is routed along
the passenger side rear quarter panel.

Rescue Lift Air Bags

Responders should not place cribbing or rescue lift air bags under
the high voltage power cables, exhaust system, or fuel system.

Repositioning Steering Wheel and Front Seats

Telescopic steering wheel and seat controls are shown in the
illustrations.

Charge Inlet Power Cable

Tilt and Telescoping Control

Front Manual Seat Controls Optional Front Power Seat Controls

Charge Inlet Power Cable

-67-

Emergency Response (2012 Model - Continued)

Extrication (Continued)

Active Headrest Removal

The Prius Plug-in hybrid is equipped with active headrests,
located in both front seatbacks. The active headrests are
mechanical non-pyrotechnic head supports that are designed to
reduce neck injuries in the event of a rear collision.

No special methods are required to remove the headrests. Push
the release button and lift to remove the headrest.

Front Active Headrest

Electrochromic Auto Dimming Rear View Mirror

Headrest

Upper Unit

Cable

Lower Uni

t

NOTE:

The Prius Plug-in hybrid is equipped with an optional
electrochromic auto dimming rear view mirror. The mirror
contains a minimal amount of transparent gel sealed between two
glass plates that will not normally leak.

Mirr

or Cross Sectio

n

Sealed Electrochromic Coating

-68-

Emergency Response (2012 Model - Continued)

preventing the responder from properly applying water through the
available vent openings safely. Therefore, it is recommended that the
incident commander allow the Prius Plug-in hybrid HV battery
assembly to burn itself out.

Fire

Approach and extinguish a fire using proper vehicle fire fighting practices as
recommended by NFPA, IFSTA, or the National Fire Academy (USA).

• Extinguishing Agent
Water has been proven to be a suitable extinguishing agent.

Defensive Fire Attack

If the decision has been made to fight the fire using a defensive attack,
the fire attack crew should pull back a safe distance and allow the Li­ion battery cells to burn themselves out. During this defensive
operation, fire crews may utilize a water stream or fog pattern to
protect exposures or to control the path of smoke.

• Initial Fire Attack

Perform a fast, aggressive fire attack.
Divert the runoff from entering watershed areas.
Attack teams may not be able to identify a Prius Plug-in hybrid until
the fire has been knocked down and overhaul operations have
commenced.

• Fire When Vehicle Charging

When extinguishing a fire when charging, the vehicle and charge
cable assembly may come in contact with water. As soon as possible,
shut off the power to the electrical outlet before disconnecting the
charge cable assembly. Perform the charge cable assembly
disconnection procedure contained in the Extrication section on page

62.

• Fire in the HV Battery Assembly
Should a fire occur in the Li-ion HV battery assembly, attack crews

should utilize a water stream or fog pattern to extinguish any fire
within the vehicle except

for the HV battery assembly.

When allowed to burn themselves out, the Prius Plug-in hybrid Li-ion

battery cells burn rapidly and are reduced to a combination of ashes
and metal components.

WARNING:

• Burning batteries may irritate the eyes, nose, and throat. To
prevent injury wear personal protective equipment suitable for
organic solvents including SCBA.

• The battery cells are contained within a metal case and
accessibility is limited.

• To avoid serious injury or death from severe burns or electric
shock, never breach or remove the high voltage battery assembly
cover under any circumstance including fire.

• To prevent serious injury or death, shut off the utility circuit
supplying power to the charge cable assembly before disconnecting
it if the CCID or charge cable assembly are submerged in water.

Offensive Fire Attack
Normally,

flooding a Li-ion HV battery assembly with copious

amounts of water at a safe distance will effectively control the HV
battery assembly fire by cooling the adjacent Li-ion battery cells to a
point below their ignition temperature. The remaining cells on fire, if
not extinguished by the water, will burn themselves out.

However, flooding the Prius Plug-in hybrid HV battery assembly is

not

recommended due to the battery case design and location

E

-69-

mergency Response (2012 Model - Continued)

Overhaul

During overhaul, immobilize and disable the vehicle if not already done.
Refer to illustrations starting on page 61, 62 and 63. The HV battery
assembly cover should never be breached or removed under any
circumstances including fire. Doing so may result in severe electrical burns,
shock, or electrocution.

• Immobilize Vehicle
Chock wheels and set the parking brake.
Push the P position switch to engage park (P).

• Disable Vehicle

Perform these steps first if the charge cable assembly is
connected to the vehicle.

1. Disconnect the charge cable assembly connector from the

vehicle. To disconnect it, push the lock release button on the top
of the connector and pull it away from the vehicle.

2. Close the recharge inlet cap and charge inlet door.

3. Disconnect the plug of the charge cable assembly from the

electrical outlet.

Performing either of the following two procedures will shut the
vehicle off and disable the HV, SRS, charging and remote air
conditioning systems.

Procedure #1

1. Confirm the status of the READY indicator in the instrument

cluster. If the READY indicator is illuminated, the vehicle is on
and operational.

2. Shut off the vehicle by pushing the power button once.

3. The vehicle is already shut off if the instrument cluster lights are

not illuminated. Do not push the power button because the
vehicle may start.

4. If the smart key is easily accessible, keep it at least 16 feet (5

meters) away from the vehicle.

5. Disconnect the 12 Volt auxiliary battery under the deck board

and auxiliary box in the cargo area to prevent accidental
restarting of the vehicle.

Procedure #2

1. Open the hood and remove the fuse box cover.

2. Remove the IG2 fuse (20A yellow colored) in the engine

compartment fuse box as illustrated on page 62. If the correct
fuse cannot be recognized, pull all fuses in the fuse box.

3. Disconnect the 12 Volt auxiliary battery under the deck board
and auxiliary box in the cargo area to prevent accidental
restarting of the vehicle.

NOTE:

Before disconnecting the 12 Volt auxiliary battery, if necessary, lower
the windows, unlock the doors, optional power seat and open the hatch
as required. Once the 12 Volt auxiliary battery is disconnected, power
controls will not operate.

WARNING:

• The high voltage system, including the charging system, may remain

powered for up to 10 minutes after the vehicle is shut off, disabled, or
charging stops. To prevent serious injury or death from severe burns
or electric shock, avoid touching, cutting, or breaching any orange
high voltage power cable or high voltage component.

• The SRS may remain powered for up to 90 seconds after the vehicle is

shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.

• If none of the disabling procedures can be performed, proceed with

caution as there is no assurance that the high voltage electrical system,
SRS, fuel pump, recharging, or remote air conditioning are disabled.

Recovery of Li-ion HV Battery Assembly

For information regarding recovery of the HV battery assembly, contact:

United States: [phone]
Canada: (888) TOYOTA 8 [[phone]]

E

-70-

mergency Response (2012 Model - Continued)

Spills

The Prius Plug-in 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.

In an emergency, the Li-ion battery (part number G9280-47130)
manufacturer’s Material Safety Data Sheet (MSDS) is available by
contacting:

United States: CHEMTREC at [phone]
Canada: CANUTEC at *666 or [phone] (collect)

• 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.

• Absorbent
Suitable absorbent for an organic solvent.

First Aid

Emergency responders may not be familiar with Li-ion electrolyte exposure
when rendering aid to a patient. Exposure to the electrolyte is unlikely except
in a catastrophic crash or through improper handling. Utilize the following
guidelines in the event of exposure.

• Wear 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

• Absorption
Perform gross decontamination by removing affected clothing and
properly disposing of the garments.
Rinse the affected areas with water for 20 minutes.
Transport patients to the nearest emergency medical care facility.

• Inhalation in Non-Fire Situations
Contact with the vapor produced by the electrolyte may irritate the
nose and throat. In severe cases such as confined spaces, move
exposed patients to a well ventilated area.
Transport patients to the nearest emergency medical care facility.

• Inhalation in Fire Situations
Toxic gases are given off as by-products of combustion. All
responders in the Hot Zone should wear the proper PPE for fire
fighting including SCBA.
Move a patient from the hazardous environment to a safe area and
administer oxygen.
Transport patients to the nearest emergency medical care facility.

Em

-71-

ergency Response (2012 Model - Continued)

First Aid (Continued)

• Ingestion
Do not induce vomiting, unless instructed by the doctor.
If vomiting occurs naturally, avoid aspiration.
Transport patients to the nearest emergency medical care facility.

Submersion

A submerged hybrid vehicle does not have high voltage potential on the metal
vehicle body, and is safe to touch.

Access Patients

Responders can access the patient and perform normal extrication
procedures. High voltage orange color coded power cables and high
voltage components should never be touched, cut, or breached.

Vehicle Recovery

If a hybrid vehicle is fully or partially submerged in water, emergency
responders may not be able to determine if the vehicle has been
automatically disabled. The Prius Plug-in hybrid may be handled by
following these recommendations:

Perform these steps first if the charge cable assembly is
connected to the vehicle (see illustrations on page 62).

1. Shut off the utility circuit supplying power to the charge cable
assembly.

2. Disconnect the charge cable assembly connector from the vehicle.
To disconnect it, push the lock release button on the top of the
connector and pull it away from the vehicle.

3. Close the charge inlet door.

4. Disconnect the plug of the charge cable assembly from the
electrical outlet.

5. Remove the vehicle from the water

6. Drain the water from the vehicle if possible

7. Follow the immobilizing and disabling procedure starting on page
61, 62 and 63.

NOTE:

If park (P) system related components are damaged due to
submersion, it may not be possible to shift from park (P) to neutral
(N). If this is the case, make sure to tow or move the vehicle with the
front wheels off the ground.

WARNING:

To prevent serious injury or death, shut off the utility circuit supplying
power to the charge cable assembly before disconnecting it if the
CCID or charge cable assembly are submerged in water.

-72-

Roadside Assistance (2012 Model)

The Prius Plug-in hybrid utilizes an electronic shift selector and a P
position switch for selecting park (P). If the 12 Volt auxiliary battery is
discharged or disconnected, the vehicle cannot be started nor can it be
shifted out of park (P). If discharged, the 12 Volt auxiliary battery can
be jump started to allow vehicle starting and shifting out of park (P).
Most other roadside assistance operations may be handled like
conventional Toyota vehicles.

Roadside assistance is available in the United States by contacting:

United States: [phone] (for the first 2 years/25,000 miles)
Canada: (888) TOYOTA 8 [(888)-869-6828] (for the first 3 years/60,000 km)

Towing

The Prius Plug-in hybrid is a front wheel drive vehicle and it must be towed
with the front wheels off the ground. Failure to do so may cause serious
damage to Hybrid Synergy Drive components.

• The vehicle may be shifted out of park (P) into neutral (N) by turning the
ignition-on and READY-on modes. To select neutral (N), it is necessary
to hold the shift selector in the N position for approximately 0.5 seconds.

• If the 12 Volt auxiliary battery is discharged, the vehicle will not start and
shifting out of park (P) is not possible. There is no manual override
except to jump start the vehicle, refer to the Jump Starting on page 75.

• If a tow truck is not available, in an emergency the vehicle may be moved
using a cable or chain secured to the emergency towing eyelet or rear tow
hook for short distances at low speeds (below 18 mph (30km/h)). The
eyelet is located with the tools under the driver seat of the vehicle, refer to
the illustration on page 74.

Starting Vehicle Move Shift Selector to N Position

Towing Eyelet Mounting Location Eyelet Installation

Rear Hook Location

Rear Hoo

k

-73-

Roadside Assistance (2012 Model - Continued)

Electric Hatch Opener Switch

Manual Hatch Release

Electric Fuel Door Opener Switch Manual Fuel Door Release

Electric Hatch Opener

The Prius Plug-in hybrid is equipped with an electric hatch opener. In the
event of 12 Volt power loss, the hatch cannot be opened from the outside of
the vehicle.

The electric hatch can be opened manually using the release as shown in the
illustration.

Hatch Opener Switch

Back Hatch, Viewed from
Inside Vehicle

Electric Fuel Door Opener

The Prius Plug-in hybrid is equipped with an electric fuel door opener. In the
event of 12 Volt power loss, the fuel door can only be opened using the
manual release located inside the cargo area.

Pull

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Roadside Assistance (2012 Model - Continued)

Emergency Tire Puncture Repair Kit

Tools, Jack and Towing Eyelet under the Driver Seat

Emergency Tire Puncture Repair Kit in the Cargo Area

The Prius Plug-in hybrid does not contain a spare tire. Instead, an emergency
tire puncture repair kit is provided in the driver side rear panel well shown in
the illustration. The jack, tools, and towing eyelet are located under the driver
seat shown in the illustration.

Towing Eyelet, Jack
and Tools

Emergency Tire
Puncture Repair Kit

Remote Hood Release Hood Latch Release

Remove Fuse Box Cover Open Positive Terminal Cover

Jumper Cable Connections

Positive Terminal

Ground

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oadside Assistance (2012 Model - Continued)

R

Jump Starting

The 12 Volt auxiliary battery may be jump started if the vehicle does not start
and the instrument cluster gauges are dim or off after depressing the brake
pedal and pushing the power button.

The 12 Volt auxiliary battery is located in the cargo area. If the 12 Volt
auxiliary battery is discharged, the rear hatch cannot be opened. Instead, the
vehicle can be jump started by accessing the remote positive 12 Volt auxiliary
battery terminal in the engine compartment fuse box.

• Open the hood, remove the fuse box cover, and open the positive terminal
cover.

• Connect the positive jumper cable to the positive terminal.

• Connect the negative jumper cable to a solid ground.

• Place the smart key in proximity to the interior of the vehicle, depress the

brake pedal, and push the power button.

NOTE:
If the vehicle does not recognize the smart key after connecting the
booster battery to the vehicle, open and close the driver door when the
vehicle is shut off.

If the smart key internal battery is dead, touch the Toyota emblem side of
the smart key to the power button during the start sequence. See the
instructions and illustrations on page 48 for more details.

• The high voltage HV battery assembly cannot be jump started.

Immobilizer

The Prius Plug-in hybrid is equipped with a standard immobilizer system.

• The vehicle can be started only with a registered smart key.