10561792

TOYOTA Hybrid Technology
1
Contents
What is the Hybrid Vehicle?
THS II (TOYOTA Hybrid System)
Engine
Hybrid Transaxle
Inverter Assembly
HV Battery
THS II Operation
ECB (Electronically Controlled Brake)
Indicator and Warning
Other System
Service Point
Other Hybrid Vehicles
2
3
Why is the hybrid vehicle necessary? (ppmv)
600
CO2 Concentration
500
400
300
Increase Automobile 1970 2006 260

1200 1400 1600 1800 2000
market
Expanding Energy 2100
Consumption
Low fuel consumption and low CO2 emission

vehicle is required
4
Why is the hybrid vehicle necessary?
– Hybrid technology is the core for eco-car development
Ultimate eco-car
•Low fuel consumption
•Low CO2 emission
THS II
FCHV
THS
DPNR D-4
CNG DPR Lean Burn EV
Common-rail VVT-i
Alternative Diesel Gasoline Electric

Energy Engine Engine Vehicle
5
Kind of Hybrid System
– Series Hybrid System
• In this system, the engine is used to supply
electrical power to the motor, which then turns the
wheels
6
– Parallel Hybrid System
• The wheels are driven by both the engine and the
motor
7
– THS (TOYOTA Hybrid System)
• Strong points of both series/parallel systems
realized in one system
8
– Concept
Low Fuel Higher

Consumption Power
9
– Hybrid vehicle realizes low fuel consumption and
higher power
Good Fuel
Economy
PRIUS
(NHW20)
PRIUS
(NHW11)
Mode Fuel Efficiency
Japanese 10 – 15
(km/L)
Corolla Tradeoff between performance

(1.3L) Corolla and fuel economy in
(1.5L) conventional vehicle
CAMRY
(2.4L)
Good Acceleration
10
0 – 100 km/h Acceleration (sec.)
Driving Method
– The vehicle can run on gasoline only, and does not
need to be recharge
– If the battery charge drops, the engine drives the
generator, which recharges the battery
11
Driving Method
– The vehicle may be driven while the “READY” light is
ON
– The engine will stop while the vehicle is stopped, in
order to improve fuel economy
– The engine starts up automatically after the vehicle
starts off
12
THS II
(TOYOTA Hybrid System)
PRIUS [NHW20]
13
Main Component Location
HV Battery
Inverter
Engine
Hybrid Transaxle
•Generator (MG1)
•Motor (MG2)
•Power-dividing Mechanism Click Movie
14
Main Component Location
Shift Lever
Parking Switch
Shift Lever
MOVIE
15
System Diagram
Click here to see

Shift Position operation of
Hybrid Transaxle Electric A/C
Sensor shift lever Compressor
(Shift, Select)
MG1 MG2
Accelerator
Pedal Position
Sensor
A/C
HV Inverter
EV Mode Inverter
ECU
Switch
Engine Boost DC – DC
ECU Converter Converter
Engine
Skid Control SMR1, 2 and 3

Brake ECU
Actuator
CAN Auxiliary
Speed Battery HV Battery
DLC3 ECU
Sensors Battery
16
Outline
– Compression from conventional vehicle
Conventional
Item THS II Note for THS II
Vehicle
•Motor drive is possible
•Engine (Engine OFF)
Power
Engine •Motor •Engine motive force is
Source
•Generator divided for drive and
electric generation
•Divide the engine, motor
Trans- •A/T Power Splitting
and generator power
mission •M/T Device
•Function as CVT
Cooperative control
•Hydraulic Brake
Brake Hydraulic Brake between hydraulic and
•Regenerative Brake
regenerative brake
•12V Battery High-voltage supply for
Battery 12V Battery
•201.6V Battery motor drive
Power •HV ECU
Controls the engine,
Train Engine ECU •Engine ECU
motor and generator
Control •Inverter
17
Outline
– System operation
Normal
Start-off Driving Acceleration Deceleration Stop
Electric Motor and Motor and Engine Battery Engine

motor only Engine (additional power charging automatically
drawn from battery) shuts off
18
1NZ-FXE Engine
– 1.5 liter, In-line 4-cylinder, 16-valve DOHC, gasoline
engine
1NZ-FXE
X = Atkinson Cycle
19
Hybrid Transaxle
– Includes AC 500V motor, generator and power-
dividing mechanism
– Uses a continuously variable transmission mechanism
to achieve smooth and quiet operations
MG2
MG1
Power-dividing
Mechanism
20
HV Battery
– Full sealed nickel metal hydride (Ni-MH) battery
– DC 201.6V
– Located behind the rear seat
21
Inverter Assembly
– Inverter
• DC  AC high voltage
– Variable-voltage System
• DC 200V stepped up to
Max. DC 500V
– DC-DC Converter
• DC 200V stepped down
to DC 12V
– A/C Inverter
• DC  AC to drive the
A/C compressor
22
Brake System
– ECB (Electrically Controlled Brake)
– Hydraulic brake pressure is controlled by electrical
signal and cooperate regenerative brake
Hydraulic
Driver’s Demand Brake Control
Skid
Control HV ECU
ECU
Regenerative
Vehicle Condition Brake Control
23
Steering System
– EPS (Electric Power Steering) is used
EPS ECU
EPS Motor
24
Air Conditioning System
– Compact, high-performance scroll compressor driven
by motor
Electric Inverter Compressor
25
Multi Display
– Energy Monitor
26
Multi Display
– Fuel consumption indicator
27
Auxiliary Battery (12V)
– Auxiliary battery supplies power to headlights, audio,
and all ECUs
– Sealed-type battery is used
Auxiliary
Battery
28
Power Cable
– Orange-colored wire harness / connector
High-voltage circuit
High-voltage Wire Harness

29
Service Plug
– Shut off the high-voltage circuit
Service Plug
Caution: Wear insulated gloves when disconnecting / connecting the

30
service plug to prevent against electrical shock
Engine
31
Engine
Atkinson Cycle
– The “X” of the 1NZ-FXE indicates the use of the
Atkinson cycle, the principle applied for this vehicle’s
engine
Atkinson cycle
High thermal efficiency
1NZ-FXE (PRIUS)
32
Engine
Overview
– Atkinson cycle
Compression Stroke < Expansion Stroke
High thermal efficiency
Compression Expansion
33
Engine
Overview
– Atkinson cycle
• Depending on the driving condition, the cylinder
volume is varied by VVT-i
Valve Timing (Intake Valve) Cylinder Volume
TDC
105º
105º 90º
VVT-i
Operation
72º
72º
BDC
34
Engine
Overview
– Specifications
Item 1NZ-FXE (’04 PRIUS) 1NZ-FE (Corolla)

No. of Cylinders & Arrangement 4-Cylinder, in-line 
16-Valve DOHC,
Valve Mechanism 
Chain Drive, VVT-I
Displacement cm3 (cu. in.) 1497 (91.3) 
Bore x Stroke mm (in.) 75.0 x 84.7 (2.95 x 3.33) 
Compression Ratio 13.0 10.5
Max. Output EEC (-W, -Q) 57 kW @ 5000 rpm 78 kW @ 6000 rpm
Max. Torque EEC (-W, -Q) 115 N·m@ 4200 rpm 145 N·m@ 4200 rpm
Open 18 - -15 BTDC 42 - -2 BTDC
Intake
Valve Close 72 - 105 ABDC 10 - 50 ABDC
Timing Open 34 BBDC 42 BBDC
Exhaust
Close 2 ATDC 
Emission Regulation STEP IV STEP III
38
Engine
Overview
– Engine compartment
Drive belt simply layout
TOYOTA Genuine Radiators (for engine and

Super LLC inverter) are one piece
39
Engine
Overview
– Interior
Non-contact type accelerator 32-bit engine ECU with

pedal position sensor CAN communication
40
Engine
Overview
– Under floor
Plastic Type Fuel

Tank (-W, -Q)
41
Engine
Engine Proper
– Piston
• Lightweight and low friction
Piston skirt portion is

reduced to friction reduction
Shape is changed
to weight reduction
223g (Corolla)
 Prius Corolla
194g (Prius)
New resin coat to

friction reduction
42
Engine
 Engine Proper
• Piston Ring
– Lower tension and thinner piston ring is used for
friction reduction
Piston
Cross section Tension Thickness Others
Ring
4.2 N 1.2 mm (0.047 in.) PVD coat is used to
Top
  improve wear
Ring
Inner Bevel Type 3N 0.8 mm (0.031 in.) resistance
3.3 N 1.2 mm (0.047 in.) Steel material is
Second
  used to improve
Ring
Taper Type 3N 1.0 mm (0.039 in.) wear resistance
17 N 2.0 mm (0.079 in.)

Oil Ring   -
8N 1.5 mm (0.059 in.)
2 Piece Type
Corolla

Prius
43
Engine
Throttle Body (ETCS-i)
Throttle valve is controlled by the HV ECU.
ETCS-i also controls the cruise control system.
44
Engine
 Cooling System
Radiators (for engine and inverter) are one piece
Front
Radiator
(for engine)
Drain Plug
(for engine)
Radiator
(for Inverter)
45
Engine
Coolant Heat Storage System
– General
• This system reduces the amount of adhesion of fuel
on the intake port wall after engine starting
Hot coolant in
Before engine start
the tank
Amount of
adhesion of
fuel is
reduced after
Hot coolant to engine start
cylinder head Heated
46
Engine
– Components
to / from
Engine Coolant heater core
Temp. Sensor
Water Pump
(for Heater)
Coolant Heat
Storage
Water Water Pump
Valve
Coolant Heat
Storage Tank
Coolant Heat Storage Reverse Side

Tank Outlet Temp. Sensor
47
Engine
– Operation
• Engine running (w/o storage operation)
Heater
Core
Cylinder Head Water

Valve
Water
Pump
Water
Cylinder Pump
Block
OF
F
48
Engine

– Operation
• Storage operation (during engine running)
Heater
Core
Cylinder Head Water

Valve
Water
Pump
Water
Cylinder Pump
Block
OF
F
Hot coolant
is stored
49
Engine Confidential

– Operation
• Storage operation (during engine running)
 Operation chart
Tank coolant temp. is
90 °C (194 °F) or
Warm-up more
Engine Storage is
Starting Others
Completed
Meets start Meets stop

conditions conditions
Storage operation (during engine running)

[Max.: 4 times]
50
Engine
– Diagnosis
• DTCs for Coolant Heat Storage System
DTC DTC
Detection Item Detection Item
No. No.
Coolant temp. sensor circuit for Water valve position sensor circuit
P1115 P1122
coolant heat storage system low
Coolant temp. sensor circuit stuck Water valve position sensor circuit
P1116 P1123
for coolant heat storage system high
Coolant temp. sensor circuit low for Coolant Path Clog Up for Coolant
P1117 P1150
coolant heat storage system Heat Storage System
Coolant temp. sensor circuit high

P1118 P1151 Coolant Heat Storage Tank
for coolant heat storage system
Coolant pump control circuit range /

P1120 Water valve position sensor circuit P2601
performance
Water valve position sensor circuit ECM / PCM internal engine off timer
P1121 P2610
stuck performance
51
Engine
– Service Point
• Coolant Replacement
 Drain engine coolant
Caution: The coolant in coolant heat storage tank is

hot even if engine and radiator are cold
1. Disconnect the coolant heat storage water pump connector

2. Remove the radiator cap
3. Connect a vinyl hose to drain cocks (engine, radiator, coolant
heat storage tank)
4. Loosen the drain cock plugs (engine, radiator, coolant heat
storage tank), and drain coolant
5. Drain the coolant in the radiator reservoir tank
52
Engine
– Service Point
 Fill engine coolant
1. Tighten the drain cock plugs and disconnect a vinyl hose (engine,
radiator, coolant heat storage tank)
2. Connect a vinyl hose to the bleeder plug of radiator and insert the
another side of hose to reservoir tank
3. Using 6 mm socket hexagon wrench, loosen the radiator bleeder plug
from service hole
4. Fill the coolant into the radiator
5. Tighten the radiator bleeder plug and install the radiator cap
6. Fill the radiator reservoir tank with coolant to the full level
7. Connect the coolant heat storage water pump connector
8. Connect the Intelligent Tester II to DLC3 and turn to IG/ON
53
Engine
– Service Point
 Fill engine coolant
9. Perform the ACTIVE TEST of water pump (coolant heat storage water
pump operates for 30 sec.)
10. Loosen the radiator bleeder plug and fill the coolant into the radiator
11. Tighten the radiator bleeder plug
12. Repeat the steps 9 to 11 until coolant cannot be added
13. Disconnect the vinyl hose
14. Warm-up engine until the thermostat is opened (inspection mode)
15. Stop the engine, and wait until the coolant gets cold
16. Fill the coolant into the radiator
17. Repeat the step 14 to 16 until coolant level stops going down
18. Check DTC and clear the DTC which relates to the water pump
54
Engine
Fuel System
(Vapor reducing fuel tank)
Reduce the amount of

fuel vapors released
when vehicle is
parked.
55
Engine
Fuel System
It is composed of two parts:
a metal outer tank,
and a plastic
membrane inside the
fuel tank.
NOTE:
Normal tank capacity
is 45 liters; tank
capacity decreases by
5 liters at –10°C.
Click!
zoom
56
Engine
Fuel System
Fuel Sender Gauge
Sub-tank is installed Sub-tank

inside the fuel tank,
inside which a fuel
pump and sender
gauge are attached.
Fuel Sender Gauge

58
Engine
Fuel System
Fuel Sender Gauge
The fuel pump and
sender gauge can not
be removed from the
fuel tank.
If the pump or gauge

malfunctions
Replace the tank

assembly
59
Engine
Drive Belt System
– A/C compressor pulley is not existing
– Simply belt layout
Adjust Bolt
Idler Pulley
Water Pump Pulley
Crank Pulley
A/C compressor
pulley is not existing
60
Hybrid Transaxle
61
Hybrid Transaxle
Overview
– P112 type
– Components:
• MG (Motor Generator) 1
• MG (Motor Generator) 2
• Power-dividing Mechanism (Planetary Gears)
• Reduction Mechanism
• Differential Mechanism
– Fluid type: ATF WS
– Capacity: 3.8 liters
62
Hybrid Transaxle
Overview
– P112 type
Chain-drive
Planetary Gears Sprocket
MG2 MG1
63
Hybrid Transaxle
Overview
– P112 type
Counter
Drive Gear
Chain-driven Counter-
Sprocket driven Gear
Reduction
Final Drive Mechanism
Pinion Gear
Final Ring
Gear
Differential
Mechanism
64
Hybrid Transaxle
MG1 / MG2
– Compact and lightweight, highly efficient AC500V
motor generator
MG1 MG2
65
Hybrid Transaxle
MG1
– Main operations  Generator
– When engine starting  Starter
Stator Coil
MG1
Rotor
Speed Sensor
66
Hybrid Transaxle
MG2
– When driving  Main power to engine power (Starting
off) or provides supplementary
– When braking  Converts kinetic energy to
electrical energy
Stator Coil MG2
Rotor
Speed Sensor
67
Hybrid Transaxle
Speed Sensor (Resolver)
– Detects position, speed and direction of MG1 / MG2
rotors
Speed Sensor
Speed Sensor (for MG2)
(for MG1)
68
Hybrid Transaxle
Transaxle Damper
– Installed at location of conventional clutch
Reduces shock which occurs when kinetic energy is

transmitted
69
Hybrid Transaxle
Cooling System
– Cooling circuit is used for both MG1 / MG2
– Separate cooling system from engine
Reservoir Reservoir Tank
Pump
MG1 / 2
Radiator
Electric
Radiator Water Pump
Inverter
70
Hybrid Transaxle
Oil Pump
– Forced lubrication system via trochoid pump used to
lubricate main shaft bearings
– Oil pump functions when engine is being driven
Oil Pump
71
Hybrid Transaxle
Mayor Different with Prius Generation III
72
Inverter Assembly
73
Inverter Assembly
Components
– Inverter
• DC  AC high voltage
– Variable-voltage System
• DC201.6V stepped up to
max. DC500V
– DC-DC Converter
• DC201.6V stepped down
to DC 12V
– A/C Inverter
• DC  AC to drives the
A/C compressor
74
Inverter Assembly
Components
Inverter Assembly
MG1
Variable-
voltage Inverter
System
MG2
HV Battery
A/C
Inverter
DC - DC
Converter
75
Inverter Assembly
Variable-voltage System
– DC 201.6V  Max. DC 500V conversion
Max. DC 500V
 
Inverter Assembly
DC 201.6V
MG1
Variable-
DC 201.6V voltage System DC500V
Inverter AC500V
•IPM (IGBT) (IPM)
•Reactor
MG2
HV Battery
: Discharge : Charge
76
Inverter Assembly
Inverter Operation
– Motor control
Motor Torque is controlled Motor Speed is controlled by
by the current value the frequency
High
High Speed
Torque
Low Low
Torque Speed
77
Inverter Assembly
DC – DC Converter
– DC201V  DC 12V
Inverter Assembly
HV Battery
Variable- MG1
voltage Inverter
System
MG2
DC – DC Converter
DC AC 201.6V AC
DC 12V
  
DC 201.6V AC AC 12V DC
Auxiliary
Battery
78
Inverter Assembly
A/C inverter
– DC201.6V  AC201.6V conversion
A/C ECU
Target DC 201.6V
Compressor HV ECU 
Speed AC 201.6V
AC 201.6V
DC 201.6V A/C Inverter
HV Battery
Electric
Inverter Assembly Inverter
Compressor
79
Inverter Assembly
Cooling System
– Cooling circuit is used for inverter assembly
– Separate cooling system from engine
Reservoir Reservoir Tank
Pump
MG1 / 2
Radiator
Electric
Radiator Water Pump
Inverter
80
HV Battery Assembly
81
HV Battery Assembly
Power Supply
– The HV battery supplies power to MG1 / MG2
– The auxiliary battery supplies power to HV ECU and
Engine ECU (all ECU)
– When both are functioning properly, the vehicle will
start
HV Battery Auxiliary Battery

(DC 201.6V) (DC 12V)
82
HV Battery Assembly
Components
Module
Current
Sensor
Battery ECU
SMR3
SMR2 SMR1
Service
Resister
Plug
Connector
83
HV Battery Assembly
Battery Module
– Nickel metal hydride (Ni-MH) battery
(1.2V x 6 cells) x 28 modules = 168 cells = DC 201.6 V
28 Module
Module
(1.2V x 6 cells)
84
HV Battery Assembly
Battery ECU
– Maintains control of HV battery SOC (State of charge)
– Ensures battery capability
Battery ECU
CAN
SOC HV Battery Cooling Fan
Battery Control Condition Detection Control
Cooling Fan
Relay Electrical Leakage Detection Diagnosis Function •HV ECU
for High-voltage System for HV Battery •Engine ECU
•A/C ECU
Battery
Cooling Fan
Controller Voltage x 14 Temp. x 4
+
Temp. Sensors
Service
(Thermistor)
Battery Plug
Cooling Fan
Motor - Current
Sensor HV Battery
85
HV Battery Assembly
Battery ECU
– Controls SOC to match THS characteristics
– The SOC is maintained at approx, 60%. A margin is
given for further recharging via regenerative braking
– Sends requests to HV ECU to obtain desired SOC
86
HV Battery Assembly
SOC Control
– When the SOC is dropped, battery ECU sends the
“Charge Request” signal to HV ECU
Battery ECU
Charge Power
SOC Request Request Engine
HV ECU
ECU
Control
Voltage
(SOC)
Charging
Charge Drive
MG1
HV Battery Engine
87
HV Battery Assembly
SMR (System Main Relay)
– Turns ON / OFF the high-voltage circuit
SMR3
SMR1
SMR2
88
HV Battery Assembly
SMR
– Shutdown control
READY OFF At Collision
Interlock Switch OFF

89 (Service plug grip disconnection, Inverter cover open)
HV Battery Assembly
Service Plug
– Shut off the high voltage circuit manually
Service Plug
90
HV Battery Assembly
Auxiliary Battery
– Auxiliary battery supplies power to headlights, audio,
and all ECUs
Auxiliary
Battery
91
HV Battery Assembly
Auxiliary Battery
– Sealed-type battery is used
Notice:
Refrain from quick charging
Because the battery fluid
cannot be replenished
Never use an ordinary battery
92
HV Battery Assembly
Auxiliary Battery
– Jump Start Terminal
• ”+” terminal of auxiliary battery for jump start is
used
Jump Start
Terminal
93
Special Notes on Service
Auxiliary Battery
– Jump Start Procedure Auxiliary Battery
Negative Terminal Positive Terminal
Click Movie
94
THS II Operation
95
THS II Operation
Components
HV Battery
Generator (MG1)
Engine
Inverter
Power-dividing
Device
Motor (MG2)
Differential
Mechanism
96
THS II Operation
Power-dividing Mechanism (Planetary Gears)
– Sun gear: MG1
– Planetary Carrier: Engine
– Ring Gear: MG2 (Front Wheel)
MG2
Engine MG1
Power-dividing
Chain Mechanism
To Front Wheel
97
Unit Planetary gear
Perangkat Pembagi Power
Unit Planetary gear Ring Gear Planetary Carrier
Sun Gear
98
Bagan Nomographic
Kondisi MG1, MG2

Arah Rotasi
+ -
Mome + Discharge (Motor) Charge (Generator)
n - Charge (Generator) Discharge (Motor)
99
Bagan Nomographic
Prinsip Kerja-1
Sun gear: fixed (tertahan)
Ring gear: berputar (input)
Planetary carrier: ?
Klik di atas untuk melihat film (movie)
 Referensi ke bagan
100
Bagan Nomographic
Prinsip Kerja-2
Planetary carrier: fixed
(tertahan)
Ring gear: berputar (input)
Sun gear: ?
Klik di atas untuk melihat film (movie)
101
THS II Operation
Engine Starting and Idling
Vehicle
Speed
Click! Click!
animasi Movie
102
Menghidupkan Mesin
Menghidupkan Mesin
MG1 bekerja sebagai motor starter
103
Menghidupkan Mesin
Starting Mesin dan Idling
Mesin menggerakkan MG1 untuk mengisi baterai HV.
104
THS II Operation
Vehicle Starting Off
Vehicle
Speed
Click! Click!
animasi Movie
105
Kendaraan Mulai Berjalan
Starting Off-1
Hanya MG2 yang digunakan dalam beban ringan/
akselerasi ringan.
106
Starting Off-2
MG1 bekerja untuk menghidupkan mesin saat
dibutuhkan tambahan power.
107
Starting Off-3
Mesin menggerakkan MG1 untuk membangkitkan listrik
untuk MG2
108
THS II Operation
Accelerating Under Low Load (Light Throttle)
– Request more power, MG1 starts engine
Vehicle
Speed
Click! Click!
animasi Movie
109
Selama Merayap (Cruising):
MG2 membangkitkan listrik untuk MG1.
Unit planetary gear bertindak sebagai CVT.
110
Akselerasi Ringan
MG1 membangkitkan listrik untuk MG2.
MG2 menyediakan power penggerak tambahan.
111
THS II Operation
Accelerating Under Heavy Load (Full Throttle)
Vehicle
Speed
Click! Click!
animasi Movie
112
Akselerasi Full Throttle
Akselerasi Full Throttle
113
THS II Operation
Decelerating
Vehicle
Speed
Click! Click!
animasi Movie
114
Deselerasi
D range
MG2 berperan sebagai generator untuk mengisi baterai
HV.
115
Deselerasi
B range
MG1 menggerakkan mesin untuk pengereman oleh
mesin.
116
THS II Operation
Driving in Reverse
Vehicle
Speed
Click! Click!
animasi Movie
117
Pengendaraan Mundur
Pengendaraan Mundur
Hanya MG2 yang digunakan untuk mundur.
118
Kontrol
Motor Traction Control
Mengontrol MG2 dan rem hidrolik.
Sensor
Kecepatan Slipping ECU Skid Kecepatan Tinggi
Control ECU
Setiap
HV
Roda
Traction
Control
Sensor
Kecepatan
MG2
Gaya
Pengereman Inverter
119
Kontrol
Kontrol Bantuan Menanjak
Mengontrol rem hidrolik belakang.
Sinyal Sensor Kecepatan MG2 dll.

ECU HV
Traction Control
ECU Skid
Control
Gaya
Pengereman
Mencegah kendaraan dari

terguling ke belakang
120
THS II Operation
THS-II Control
– Motor Drive Mode Control (except U.S.A. model)
• In this mode, the vehicle is driven by only MG2 by
operating the EV Mode Switch
EV Engine ECU
Mode
Combination Switch Battery ECU
Meter
•SOC Condition
EV Mode Gateway •Battery Temp.
Indicator
Light
ECU
HV ECU HV
Battery
Accelerator Pedal Drive
Position Sensor
Inverter
Speed Skid Control
Sensors ECU
121
THS II Operation
THS-II Control
• EV Mode Switch is momentary type
EV Mode
Switch
LHD Model
122
THS II Operation
THS-II Control
• Operation conditions
Push
Normal EV Mode
EV mode canceling conditions

•EV mode switch is pushed
•HV battery SOC drops
•HV battery temp. is low or high
or •Engine is warming up
•Vehicle speed exceeds the
specified speed
•The accelerator pedal position
angle exceeds the specified value
123
ECB
(Electronically Controlled Brake)
124
General
– The total brake force provided by both hydraulic and
regenerative brakes matches the braking power
required
Regenerative Brake Hydraulic Brake
125
ECB Operation
– Hydraulic brake pressure is generated electrically
(brake by wire)
ECB Vehicle Brake Force

Generation
Skid Control
Sensor Control
ECU
Conventional Vehicle
Brake Force
Generation
126
127
Combination Meter
– READY light indicates that the vehicle is ready to drive
Ready Light
128
Multi Display
– Energy monitor shows the energy flow
129
Multi Display
– Warning display
• Warning marks
High Engine
Oil EPS
Discharge Coolant
Pressure Warning
Warning Temperature
Warning
Warning
Automatic
Hybrid HV Headlight
System Battery Leveling System
Abnormal Warning Warning
130
Multi Display
– Warning message
131
Other Systems
132
Other Systems
General
– Engine is operated intermittently, so power steering
and A/C compressor uses electric power
EPS (Electric Power Steering) Electric Inverter Compressor
133
Other Systems
EPS (Electric Power Steering)
– Column assist type EPS is used
EPS ECU
DC Motor
(12V)
Reduction Torque Sensor

Mechanism
Column Assist Type EPS

134
Other Systems
Air Conditioning
– Service Point
• Don’t use the compressor oil other than ND11
135
Service Point
136
Service Point
Inspection Mode
– In the inspection mode, engine is continuously
operated (P range) and motor TRC is turned off
Transferring
Mode Vehicle Condition Purpose
Procedure
•Manual
Inspection Mode- •Keeps engine •Exhaust gas test
procedure
2WD Inspection running (P range) •Engine adjusting
•Intelligent tester
(Inspection Mod1) •Motor TRC is OFF •Speedometer test
(Active Test)
Inspection Mode-
Speedometer test
2WD Chassis- Intelligent tester
Motor TRC is OFF (chassis
Dynamo (Active Test)
dynamometer)
(Inspection Mod2)
Note: Other hybrid vehicle has several types of inspection mode.

137 For derails, please refer to the repair manual.
Service Point
Inspection Mode
– Manual procedure
within 60 seconds
with brake
Accelerator
Pedal
OFF

IG-ON
IG-ON

Depress Depress Depress READY
twice twice twice
Change the power mode to OFF  inspection mode is canceled

138
Click Movie
Service Point
– All high-voltage wire harness and connectors are
colored orange

Click Movie
139
Service Point
– Use a megohmmeter to measure the insulation
resistance (Standard: 2  10 M)
Megohmmeter It cannot check the

insulation resistance
correctly by the TOYOTA
Electrical Tester
Basically use the 500V range
Notice: If you use the 1000V range, it
causes the breakdown of the parts
140
Service Point
– Risk of electric shock
Case Condition Risk of Electric Shock
Touch the high-voltage + side No risk
Touch the body (high-voltage - side)

No risk
when there is a electrical leakage
Touch the high-voltage + side when Possibility of

there is a electrical leakage electric shock
Touch the high-voltage + and - side Electric shock !
141
Service Point
Safety Precautions
– Before servicing the high voltage area
• Make sure to perform the followings;
1. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH

DURING OPERATION" sign
2. Turn the power mode to off
3. Remove the key from key slot and carry the key
4. Disconnect auxiliary battery negative terminal
5. Check the insulated gloves
6. Remove the service plug
7. Wait 5 min. or more
8. Measure the inverter terminal voltage (0V check)
142
Service Point
Safety Precautions
5. Before servicing the high voltage area
Wait 10 minutes or more to discharge high-voltage
condenser in the inverter
High-voltage Condenser
Discharge
Inverter
Elect- 0V Assembly
ricity
Service plug 5 min.

disconnection
143
Service Point
Safety Precautions
1.Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH
DURING OPERATION" sign to notify other engineers
144
Service Point
Safety Precautions
5.Check the insulated gloves
Not cracked, ruptured, torn,

or damaged
Not wet
145
Service Point
Safety Precautions
6.Remove the service plug
Service Plug
Remove before servicing
146
Service Point
Safety Precautions
8.Measure the inverter terminal voltage (0V check)
Between
3 phases
3 phases and
body ground
Inverter Assembly
147
Service Point
Safety Precautions
– During servicing the high voltage area
• Insulate the tools by vinyl tape
Insulated Vinyl Tape
148
Service Point
Safety Precautions
• Insulate the disconnected high-voltage connector
with insulated vinyl tape
Insulated Vinyl Tape
149
Service Point
Safety Precautions
• Non-reusable nut is used to the installation of high
voltage line
New Example of use
Wire x SMR
Used
Non- Junction Block x Module
150
reusable
Service Point
Safety Precautions
– After servicing the high voltage area
• Before reinstalling the service plug, check again the
following
You have not left a part or

tool inside
The high-voltage terminal

nuts and screws are properly
tightened
The connectors are correctly

connected
151
Service Point
Safety Precautions
– After servicing the high voltage area
• Be sure to install the service plug before starting the
hybrid system
Vehicle
damages
After
servicing
Installation
152 READY ON
Service Point
Response When The HV Battery (201.6V) Runs Out
– Vehicle conditions when HV battery low voltage
 HV Battery Warning Light illuminates
 Can not READY ON
 DTC P3000-389 (HV Battery Malfunction) is

detected
153
Service Point
Response When The HV Battery (201.6V) Runs Out
– Charge the HV Battery using THS Charger
THS
Charger
THS Charger
Note: THS charger is the recommended tool

154
Service Point
Battery Pack Removal / Installation
– If the HV battery electrolyte leaks, don’t touch it
Neutralize
battery
electrolyte
Boric Acid Solution
Don’t touch the battery

electrolyte !
Boric Acid Water

(800 g) (20 liters)
155
Service Point
Towing
Notice: If there is a electrical leakage, motor regenerates

156 the electricity by wheel rotation

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TOYOTA Hybrid Technology

Increase Automobile 1970 2006 260

Low fuel consumption and low CO2 emission

CNG DPR Lean Burn EV

Alternative Diesel Gasoline Electric

Low Fuel Higher

Corolla Tradeoff between performance

Click here to see

Skid Control SMR1, 2 and 3

Electric Motor and Motor and Engine Battery Engine

Electric Inverter Compressor

High-voltage Wire Harness

High-voltage Wire Harness

Caution: Wear insulated gloves when disconnecting / connecting the

High thermal efficiency

Compression Stroke < Expansion Stroke

High thermal efficiency

Valve Timing (Intake Valve) Cylinder Volume

Item 1NZ-FXE (’04 PRIUS) 1NZ-FE (Corolla)

Drive belt simply layout

TOYOTA Genuine Radiators (for engine and

Non-contact type accelerator 32-bit engine ECU with

Plastic Type Fuel

Piston skirt portion is

New resin coat to

17 N 2.0 mm (0.079 in.)

ETCS-i also controls the cruise control system.

Coolant Heat Storage Reverse Side

Cylinder Head Water

Coolant Heat Storage System

Cylinder Head Water

Coolant Heat Storage System

Meets start Meets stop

Storage operation (during engine running)

Coolant temp. sensor circuit high

Coolant pump control circuit range /

Caution: The coolant in coolant heat storage tank is

1. Disconnect the coolant heat storage water pump connector

Reduce the amount of

Sub-tank is installed Sub-tank

Fuel Sender Gauge

If the pump or gauge

Replace the tank

Water Pump Pulley

Reduces shock which occurs when kinetic energy is

Reservoir Reservoir Tank

Mayor Different with Prius Generation III

Reservoir Reservoir Tank

HV Battery Auxiliary Battery

READY OFF At Collision

Interlock Switch OFF

Unit Planetary gear Ring Gear Planetary Carrier

Kondisi MG1, MG2

Klik di atas untuk melihat film (movie)

Klik di atas untuk melihat film (movie)

Sinyal Sensor Kecepatan MG2 dll.

Mencegah kendaraan dari

EV mode canceling conditions

Regenerative Brake Hydraulic Brake

ECB Vehicle Brake Force

EPS (Electric Power Steering) Electric Inverter Compressor

Reduction Torque Sensor