Toyota Prius ZVW35 Series Dismantling Manual

Plug-in Hybrid

Gasoline-Electric
Hybrid Synergy Drive

ZVW35 Series

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Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius Plug-in
gasoline-electric hybrid vehicles. Prius Plug-in hybrid dismantling procedures are similar to other
non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to
recognize and understand the high voltage electrical system features and specifications of the Toyota
Prius Plug-in hybrid, as they may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
Prius Plug-in hybrid to help ensur e the high voltage, approximately

346*1 or 207.2*2 Volt, Lithium-ion

(Li-ion) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The Li-ion 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 electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and co nnectors, are isolated from the metal chassis
of the vehicle.

*1: 2010 Model
*2: 2012 Model

Additional topics contained in the guide include:

• Toyota Prius Plug-in hybrid identification.

• Major hybrid component locations and descriptions.

By following the information in this guide, dismantlers will be able to handle Prius Plug-in
hybrid-electric vehicles as safely as the dismantling of a conventional non-hybrid automobile.

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 .

Key Identification Points:

Charge inlet door

Exterior Rear and Left Side View

Exterior Front and Left Side View

2010 Model

Charge Inlet Door

2012 Model

Charge Inlet Door

2012 Model

2010 Model

2010 Model

2012 Model

© 2011 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.

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Table of Contents

About the Prius Plug-in hybrid (2010 Model)............................................................................................1

Prius Plug-in hybrid Identification (2010 Model)......................................................................................2

Exterior .........................................................................................................................................................3

Interior...........................................................................................................................................................4

Engine Compartment....................................................................................................................................5

Hybrid Component Locations & Descriptions (2010 Model) ...................................................................6

Specifications................................................................................................................................................7

Hybrid Synergy Drive Operation (2010 Model)........................................................................................8

Vehicle Operation..........................................................................................................................................8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model)................................................9

HV Battery Pack............................................................................................................................................9

Components Powered by the HV Battery Pack.............................................................................................9

HV Battery Pack Recycling.........................................................................................................................10

Auxiliary Battery..........................................................................................................................................10

High Voltage Safety (2010 Model).............................................................................................................11

High Voltage Safety System........................................................................................................................11

Service Plug Grip........................................................................................................................................12

Precaution to be observed when dismantling the vehicle (20 10 Model) .................................................13

Necessary Items.........................................................................................................................................13

Spills (2010 Model).....................................................................................................................................14

Dismantling the vehicle (2010 Model).......................................................................................................15

Removal of HV battery (2010 Model).......................................................................................................19

HV Battery Caution Label (2010 Model) .................................................................................................35

About the Prius Plug-in hybrid (2012 Model)..........................................................................................36

Prius Plug-in hybrid Identification (2012 Model)....................................................................................37

Exterior .......................................................................................................................................................38

Interior.........................................................................................................................................................39

Engine Compartment..................................................................................................................................40

Hybrid Component Locations & Descriptions (2012 Model) .................................................................41

Specifications..............................................................................................................................................42

Hybrid Synergy Drive Operation (2012 Model)......................................................................................43

Vehicle Operation........................................................................................................................................43

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2012 Model)..............................................44

HV Battery Pack..........................................................................................................................................44

Components Powered by the HV Battery Pack...........................................................................................44

HV Battery Pack Recycling.........................................................................................................................45

Auxiliary Battery..........................................................................................................................................45

v

High Voltage Safety (2012 Model)

............................................................................................................. 46

High Voltage Safety System........................................................................................................................46

Service Plug Grip........................................................................................................................................47

Precaution to be observed when dismantling the vehicle (20 12 Model) .................................................48

Necessary Items.........................................................................................................................................48

Spills (2012 Model).....................................................................................................................................49

Dismantling the vehicle (2012 Model).......................................................................................................50

Removal of HV battery (2012 Model).......................................................................................................55

HV Battery Caution Label (2012 Model) .................................................................................................69

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:

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.

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.

Plug-in EV (Electric Vehicle) Mode:

 Utilizing the charge cable assembly connected to a 120 Volt outlet, the vehicle’s HV battery can be

charged within 4 hours.

 When the HV battery is sufficiently charged, the vehicle will basically run on the power of the

motor.

 If the vehicle exceeds 100 km/h or accelerates suddenly when traveling in plug-in EV mode, the

gasoline engine and motor work together to power the vehicle.

HV (Hybrid Vehicle) Mode:

 During light acceleration at low speeds, the vehicle is powered by the electric motor. The gasoline

engine is shut off.

 During normal driving, the vehicle is powered mainly by the gasoline engine. The gasoline engine

also powers the generator to recharge the battery assembly.

 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 front

wheels to produce electricity that recharges the battery assembly.

 While the vehicle is stopped, the gasoline engine and electric motor are off, however the vehicle

remains on and operational.

 Hard Acceleration

 Normal Driving

Plug-in EV Mode

HV (Hybrid Vehicle) Mode

 Plug-in Charging

Engine
automatically
stopped

Charging batteriesElectricity and gasoline

Electricity and gasoline
(additional electricity
extracted from batteries)

Electricity

Electricity and gasoline

Electricity

Plug-in charging

1

Prius Plug-in hybrid Identification (2010 Model)

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 left side door pillar.

Example VIN: JTDKN3DPA82020211 or JTDKN36PA82020211

A Prius Plug-in hybrid is identified by the first 8 alphanumeric characters JTDKN3DP or JTDKN36P.

Left Side Windshield and Left Side Door Pillar

2

Prius Plug-in hybrid Identification (2010 Model - Continued)

Exterior

 logo on the front right fender.

 Charge inlet door with

logo, located on left side front fender.

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

Exterior Left Side View

Exterior Front and Rear View

Exterior Rear and Left Side View













3

Prius Plug-in hybrid Identification (2010 Model - Continued)

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, the instrument cluster gauges will be “blacked out”, not illuminated.

Interior View

Instrument Cluster View





4

Prius Plug-in hybrid Identification (2010 Model - Continued)

Engine Compartment

 1.8-liter aluminum alloy gasoline engine.
 Logo on the plastic engine cover.
 Orange colored high voltage power cables.

Engine Compartment View

Power Cables









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6

Hybrid Component Locations & Descriptions (2010 Model)

Component Location Description

12 Volt  Auxiliary
Battery

Right Side of
Cargo Area

A lead-acid battery that supplies power to the low voltage

devices.
Hybrid  Vehicle (HV)
Battery Assembly

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 permanent magnet 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.

*Numbers in the component column apply to the illustrations on the following page.

Hybrid Component Locations & Descriptions (2010 Model - Continued)

Specifications

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

Electric Motors 80 hp (60 kW), Permanent Magnet Motor

Transmission: Automatic Only (electrically controlled continuously variable transaxle)

HV Battery: 346 Volt Sealed Li-ion

Battery

Curb W eight:

3,362 lbs/1,525 kg

Fuel Tank: 11.9 gals/45.0 liters

Frame Material: Steel Unibody

Body Material: Steel Panels except for Aluminum Hood and Back Door

Seating Capacity: 5 standard



















7

Hybrid 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 illuminated, it informs the driver that the vehicle is on and
operational even though the gasoline engine may be off and the engine compartment is silent.

Vehicle Operation

• With the Prius 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 is off.

The vehicle may be powered by:

1. The electric motor only.

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

Instrument Cluster READY Indicator

8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model)

The Prius Plug-in hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed
Lithium-ion (Li-ion) battery cells.

HV Battery Pack

• The HV battery pack is enclosed in a metal case and is rigidly mounted to the cargo area floor pan
cross member behind the rear seat. The metal case is isolated from high voltage and concealed by
carpet in the cabin area.

• The HV battery pack consists of 96 low voltage (3.6 Volt) Li-ion battery cells connected in series to
produce approximately 346 Volts. Each Li-ion battery cell is non-spillable and in a sealed case.

• The electrolyte used in the Li-ion battery cell is an organic solvent containing lithium-ion. The
electrolyte is absorbed into the electrode and will not normally leak, even in a collision.

HV Battery Assemb ly
Battery assembly voltage 346 V
Number of Li-ion battery cells in the battery 288 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)

Components Powered by the HV Battery Pack

• Electric Motor • Inverter/Converter Motor

• Power Cables • A/C Compressor

• Electric Generator

9

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (2010 Model ­Continued)

HV Battery Pack Recycling

• The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV
battery Caution Label (see page 35) or the nearest Toyota dealer.

Auxiliary Battery

• The Prius Plug-in hybrid also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery
powers the vehicle electrical system similar to a conventional vehicle. As with other conventional
vehicles, the auxiliary battery is grounded to the metal chassis of the vehicle.

• The auxiliary battery is located in the cargo area. It is concealed by a fabric cover on the right side
in the rear quarter panel well.

346 Volt HV Battery Pack Mounted in Cargo Area 12 Volt Auxiliary Battery Mounted in Cargo Area

10

High Voltage Safety (2010 Model)

The HV battery pack powers the high voltage electrical system with DC electricity. Positive and
negative orange colored high voltage power cables are routed from the battery pack, 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 3-phase AC to power the motors.
Power cables are routed from the inverter/converter to each high voltage motor (electric motor, electric
generator, and A/C compressor). The following systems are intended to help keep occupants in the
vehicle and emergency responders safe from high voltage electricity:

High Voltage Safety System

• A high voltage fuse * provides short circuit protection in the HV battery pack.

• Positive and negative high voltage power cables * connected to the HV battery pack are

controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays stop
electricity flow from leaving the HV battery pack.

WARNING:



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

• Both positive and negative power cables * are insulated from the metal chassis, so there is no
possibility of electric shock when touching the metal chassis.

• A ground-fault monitor continuously monitors for high voltage leakage to the metal chassis while
the vehicle is running. If a malfunction is detected, the hybrid vehicle computer * will

illuminate the master warning light

in the instrument cluster and indicate “CHECK HYBRID

SYSTEM” on the multi-information display.

• The HV battery pack relays will automatically open to stop electricity flow in a collision sufficient
to activate the SRS.

*Numbers apply to the illustration on the following page.

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High Voltage Safety (2010 Model - Continued)

Service Plug Grip

• The high-voltage circuit is cut by removing the service plug grip (see page 16).

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

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















Inverter/
Converter

Volts DC

Volts D C

A/C
Compressor

Electric
Generator

Electric
Motor

AC
3-Phase

12 Volts
Auxiliary
Battery

12 Volts
Auxiliary
Battery

Volts DC

AC
3-Phase

Electric
Motor

Electric
Generator

A/C
Compressor

Inverter/
Converter

Volts D C

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Precaution to be observed when dismantling the vehicle (2010 Model)

WARNING:

 The high voltage system may remain powered for up to 10 minutes

after the vehicle is shut off or disabled. To prevent serious injury
or death from severe burns or electric shock, avoid touching,
cutting, or opening any orange high voltage power cable or high
voltage component.

Necessary Items

• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,

and safety shoes.

• Insulating tape such as electrical tape that has a suitable electrical insulation rating.

• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in

any way. Do not wear wet insulated gloves.

• An electrical tester that is capable of measuring DC 750 Volts or more.

13

Spills (2010 Model)

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 wear personal
protective equipment for organic electrolyte including SCBA or protective mask
for organic gases.

• Handle Li-ion electrolyte spills using the following Personal Protective Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are not acceptable for electrolyte

spills.
Rubber gloves or gloves suitable for organic solvents.
Apron suitable for organic solvents.
Rubber boots or boots suitable for organic solvents.
Protective mask for organic gases or SCBA.

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Dismantling the vehicle (2010 Model)

The following 2 pages contain general instructions for use when working on a Prius Plug-in hybrid.
Read these instructions before proceeding to the HV battery removal instructions on page 19.

WARNING:



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

2. Shut off the ignition (READY indicator is off).

Then disconnect the cable from the auxiliary
battery negative (-) terminal.

(1) Remove the auxiliary battery cover.
(2) Remove the tire repair kit and styrofoam insert.
(3) Disconnect the battery negative terminal.

15

3. Remove the 3 service plug grips.

Caution:
Wear insulated gloves for the following 3 steps.

(1) Slide the handle of the service plug grip to the left.
(2) Raise the release handle of the service plug grip
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.

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4. Carry the removed service plug grip in your pocket to prevent other staff from accidentally
reinstalling it while you are dismantling the vehicle.

5. Make other staff aware that a high-voltage system is being dismantled by using the following
sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 18).

6. If the service plug grip cannot be removed due to damage to the vehicle, remove the IGCT
fuse (30A) and AM2 fuse (7.5A).

Caution:
This operation shuts off the HV system. Be sure to wear insulated gloves because
high voltage is not shut off inside the HV battery. When it is possible to remove the
service plug grip, remove it and continue the procedure.

A

M2 fuse

IGCT fuse

7. After disconnecting or exposing a
high-voltage connector or terminal, insulate
it immediately using insulating tape.
Before disconnecting or touching a bare
high-voltage terminal, wear insulated gloves.

1. Check the HV battery and nearby area for

leakage. If you find any liquid, it may be
Li-ion electrolyte. Handle Li-ion electrolyte

spills using the following Personal Protective
Equipment (PPE):

• Splash shield or safety goggles. Fold down helmet shields are not acceptable for electrolyte

spills.

• Rubber gloves or gloves suitable for organic solvents.

• Apron suitable for organic solvents.

• Rubber boots or boots suitable for organic solvents.

• Protective mask for organic gases or SCBA.

Caution:

•

The Li-ion battery contains organic electrolyte. Only a small amount may leak from
the batteries which may irritate the eyes, nose, throat, and skin.

•

Contact with the vapor produced by the electrolyte may irritate the nose and throat.

•

To avoid injury by coming in contact with the electrolyte or wear personal protective
equipment for organic electrolyte including SCBA or protective mask for organic
gases.

8. If the electrolyte comes into contact with your eye(s), call out loudly for help. Do not rub
your eye(s). Instead, wash the eye(s) with a dilute boric acid solution or a large amount of
water and seek medical care.

9. With the exception of the HV battery, remove parts by following procedures which are
similar to conventional Toyota vehicles. For the removal of the HV battery, refer to the
following pages.

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