Toyota Prius ZVW30 Series, Prius Dismantling Manual
Gasoline-Electric Hybrid Synergy Drive
ZVW30 Series
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius
gasoline-electr ic hybrid vehicles. Prius dismantling procedures are similar to other non-hybrid Toyota
vehicles with the exception of the high voltage electrical system. It is important to r e c ognize and
understand the high voltage electrical system features and specifications of the Toyota Prius hybrid, as
they may not be familiar to dismantlers.
High voltage electricity po wers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
Prius to hel p ensure the high voltage, approximately 201.6 Volt, Nickel Metal Hydride (NiMH) Hybrid
Vehicle (HV) battery pack is kept safe and secure in an accident.
The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the elec t rolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehic le.
Additional topics contained in the guide include:
• Toyota Prius identification.
• Major hybrid component locations and descriptions.
By following the information in this g uide , dismantlers will be able to handle Prius-electric vehicles as
safely as the dismantling of a conventional non-hybrid automobile.
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2009 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.
Table of Contents
About the Prius .......................................................................................................................................... 1
Prius Identification .................................................................................................................................... 2
Exterior ......................................................................................................................................................... 3
Prius Identificatio n (Continued) .............................................................................................................. 4
Interior ........................................................................................................................................................... 4
Engine Compartment .................................................................................................................................... 5
Hybrid Component Loca tions & Descriptions ........................................................................................ 6
Specifications ................................................................................................................................................ 7
Hybrid Synergy Drive Operation ............................................................................................................. 8
Vehicle Operation .......................................................................................................................................... 8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery ..................................................................... 9
HV Battery Pack ............................................................................................................................................ 9
Components Powered by the HV Battery Pack ............................................................................................. 9
HV Battery Pack Recycling ......................................................................................................................... 10
Auxiliary Battery .......................................................................................................................................... 10
High Voltage Safety ................................................................................................................................. 11
High Voltage Safety System........................................................................................................................ 11
Service Plug Grip ........................................................................................................................................ 12
Precaution to be observed whe n dismantling the vehicle ..................................................................... 13
Necessary Items ......................................................................................................................................... 13
Spills .......................................................................................................................................................... 14
Dismantling the vehicle ........................................................................................................................... 15
Removal of HV battery ........................................................................................................................... 18
HV Battery Caution Label ........................................................................................................................... 28
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About the Prius
Starting
Normal Driving
Acceleration
Deceleration
Stopping
Electricity
Electricity and gasoline
Electricity and gasoline
Charging batteries
Engine automatically
The Prius continues into its 3rd generation as a gasoline-electric hybrid vehicle.
Hybrid Synergy Drive means that the vehicle contains a gasoline engine and electric
motors for power. The two hybrid power sources are stored on board the vehicle:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the
electric motor.
The result of combining these two power sources is improved fuel economy and
reduced emissions. The gasoline engine also powers an electric generator to recharge
the battery pack; unlike a pure all electric vehicle, the Prius never needs to be recharged
from an external electric power source.
Depending on the driving conditions one or both sources are used to power the vehicle.
The following illustration demonstrates how the Prius operates in various driving
modes.
During light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery pack.
During full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the wheels to produce electricity that recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor are off, however
the vehicle remains on and operational.
(additional electricity
extracted from batteries)
1
stopped
Prius Identification
Driver Side Windshield and Driver Side B Pillar
In appearance, the 2010 model year Prius 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.
Example VIN: JTDKN3DUA82020211 or JTDKN36UA82020211
A Prius is identified by the first 8 alphanumeric characters JTDKN3DU or JT DKN36U.
2
Prius Identification (Continued)
Exterior Driver Side View
Exterior
and logos on the back door.
Gasoline fuel filler door located on driver side rear quarter panel.
logo on each front fender.
Exterior Front View Exterior Rear View
Exterior Rear and Driver Side View
3
Prius Identification (Continued)
Instrument Cluster View
Interior
Instrument cluster (speedometer, READY light, shift position indicators, warning lights)
located in center of the dash and near the base of the windshield.
Hint:
If the vehicle is shut off, t he instrument cluster gauges will be “blacked out”, not
illuminated.
Interior View of Front Door Sill/Scuff Plate
4
Prius Identification (Continued)
Engine Compartment View
Engine Compartment
1.8-liter aluminum alloy gasoline engine.
High voltage inverter/converter assembly with logo on the cover.
Orange colored high voltage power cables.
Power Cables
5
Hybrid Component Locations & Descriptions
12 Volt
Auxiliary Battery
Passenger Side of
Cargo Area
A lead-acid battery that supplies power to the low voltage
devices.
Hybrid Vehicle
Cargo Area,
Rear Seat
201.6 Volt Nickel Metal Hydride (NiMH) battery pack
Power Cables
Undercarriage and
Orange colored power cables carry high voltage Direct
inverter/converter, electric motor, and generator.
Inverter/
Engine
Boosts and inverts the high voltage electricity from the
battery pack.
Gasoline
Engine
Provides two functions:
vehicle computer.
Electric
Engine
3-phase high voltage AC permanent magnet electric motor
front wheels.
Electric
Engine
3-phase high voltage AC generator that is contained in the
A/C Compressor
Engine
3-phase high voltage AC electrically driven motor
Fuel Tank and Fuel
Undercarriage and
The fuel tank provides gasoline via a fuel line to the
Component Location Description
(HV) Battery Pack
Converter
Engine
Motor
Generator
Mounted to Cross
Member behind
Engine
Compartment
Compartment
Compartment
Compartment
Compartment
consisting of 28 low voltage (7.2 Volt) modules connected
in series.
Current (DC) between the HV battery pack,
inverter/converter, and A/C compressor. These cables
also carry 3-phase Alternating Current (AC) between the
HV battery pack to 3-phase AC electricity that drives the
electric motors. The inverter/converter also converts AC
electricity from the electric generator and electric motors
(regenerative braking) to DC that recharges the HV
1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the
contained in the front transaxle. It is used to power the
transaxle and recharges the HV battery pack.
(with Inverter)
Line
*Numbers in the component column apply to the illustrations on the following page.
6
Compartment
Center
compressor.
engine. The fuel line is routed under the center of
vehicle.
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