Toyota Prius ZVW41 Series, Prius V Dismantling Manual

Gasoline-Electric
Hybrid Synergy Drive

ZVW41 Series

ii

Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius V
gasoline-electric hybrid vehicles. Prius V dismantling procedures are similar to other non-hybrid
Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize
and understand the high voltage electrical system features and specifications of the Toyota Prius V
hybrid, as they may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
Prius V to help 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 electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.

Additional topics contained in the guide include:

• Toyota Prius V identification.

• Major hybrid component locations and descriptions.

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

© 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 V......................................................................................................................................1

Prius V Identification................................................................................................................................2

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

Prius V Identification (Continued)...........................................................................................................4

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

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

Hybrid Component Locations & Descriptions........................................................................................6

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

Hybrid Synergy Drive Operation.............................................................................................................8

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

Hybrid Vehicle (HV) 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 V oltage Safety.................................................................................................................................11

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

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

Precaution to be observed when dismantling the vehicle.....................................................................13

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

Spills..........................................................................................................................................................14

Dismantling the vehicle...........................................................................................................................15

Removal of HV battery...........................................................................................................................18

HV Battery Caution Label ...........................................................................................................................26

About the Prius V

The Prius V wagon joins the PRIUS, CAMRY hybrid and HIGHLANDER hybrid as a
hybrid model for Toyota. Hybrid Synergy Drive means that the vehicle contains a
gasoline engine and an electric motor for power. The two hybrid power sources are
stored on board the vehicle:

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

2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery 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 V never needs to be
recharged from an external electric power source.

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

n During light acceleration at low speeds, the vehicle is powered by the electric motor.

The gasoline engine is shut off.

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

gasoline engine also powers the generator to recharge the battery pack.

p During full acceleration, such as climbing a hill, both the gasoline engine and the

electric motor power the vehicle.

q During deceleration, such as when braking, the vehicle regenerates the kinetic

energy from the wheels to produce electricity that recharges the battery pack.

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

the vehicle remains on and operational.

1

r Stopping

n Starting

o Normal Driving

p Acceleration

q

Deceleration

Electricity Electricity and gasoline

Charging batteries

Electricity and gasoline
(additional electricity
extracted from batteries)

Engine automatically
stopped

Prius V Identification

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

The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front
windshield cowl, right side floor and on the left side B pillar.

Example VIN: JTDZN3EU0C3000101

A Prius V is identified by the first 8 alphanumeric characters JTDZN3EU.

Left Side Windshield, Right Side Floor and Left Side Door Pillar

2

Prius V Identification (Continued)

Exterior

and logos on the back door. n

o logo on each front fender.

Exterior Left Side View

Exterior Front View Exterior Rear View

Exterior Rear and Left Side View

o

n n o

n

n

3

Prius V Identification (Continued)

Interior

p Instrument cluster (speedometer, READY light, shift state 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 V iew of Front Door Sill/Scuf f Plate

Instrument Cluster View

p

p

READY Indicator

Shift State Indicator

4

Prius V Identification (Continued)

Engine Compartment

q 1.8-liter aluminum alloy gasoline engine.
r Logo on the plastic engine cover.
s Orange colored high voltage power cables.

Engine Compartment View

Power Cables

r

q

s

5