Gasoline-Electric Hybrid

Foreword
This guide was developed to educate and assist emergency responders
in the safe handling of the Toyota Prius gasoline-electric hybrid
vehicle following an incident. Prius emergency response procedures
are similar to other 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 as they may not be familiar to emergency responders.

High voltage electricity powers an electric motor, generator, and

inverter. All other conventional automotive electrical devices such as
the headlights, radio, and gauges are powered from a separate 12-Volt
battery. Numerous safeguards have been designed into the Prius to
help ensure the high voltage, approximately 274-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 laptop computers, cell phones, 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. These cables are
routed underneath and inboard the floor pan reinforcement which
would not normally be accessed by emergency responders at the
scene of an accident.

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Additional topics contained in the guide include:

• Toyota Prius identification.

• Major hybrid component locations and descriptions.

• Extrication, fire, recovery, and other emergency response

information.

• Roadside assistance information.

By following the information in this guide, emergency responders

will be able to handle the Prius hybrid-electric vehicle as safely as the
emergency response of a conventional gasoline engine automobile.

Note:
This Prius Emergency Response Guide (Revised) supercedes
the earlier Prius Emergency Response Guide published by
Toyota Motor Corporation in 2000 (Publication No
OTH020U)

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(BLANK PAGE)

iv
Table of Contents Page
About the Prius 1

Prius Identification 3

Hybrid Component Locations & Descriptions 7

Gasoline-Electric Hybrid Vehicle Operation 9

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery 11

High Voltage Safety 13

SRS Airbags and Seat Belt Pretensioners 15

Emergency Response 17

Extrication 17
Fire 21
Overhaul 22
Recovery/Recycling NiMH HV Battery Pack 22
Spills 23
First Aid 23
Submersion 24

Roadside Assistance 25

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About the Prius
The Toyota Prius is a gasoline-electric hybrid vehicle sold in North
America since May 2000. Gasoline-electric hybrid means the vehicle
contains a gasoline engine and an electric motor for power. Two
energy 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 increased fuel

economy and reduced emissions. The gasoline engine also powers an
electric generator to recharge the battery pack; so, 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 illustrations demonstrate how the
Prius operates in various driving modes.

On 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 is also used to recharge the
battery pack.

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

 During deceleration, such as braking, the vehicle regenerates the

kinetic energy from the front 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.

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Prius Identification
In appearance, the Prius is similar to a compact 4-door sedan.
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 driver door post.

Example VIN: JT2BK12U810020208

(A Prius is identified by the first 6 alphanumeric characters JT2BK1)

VIN Plate Locations

Exterior Front View

3
Exterior

TOYOTA Hybrid & PRIUS logos on trunk.
 Gasoline fuel filler door located on passenger side quarter panel.
 HV battery pack air vent on the driver side C-pillar.
 Toyota logo on the hood.

TOYOTA
Hybrid

Exterior Rear & Passenger Side View

Exterior Driver Side View

Exterior Front & Driver Side View

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Prius Identification (Continued)
Interior
 Column mounted automatic transmission shift lever.
 Instrument cluster (speedometer, fuel gauge, warning lights) located in
center dash and near the base of the windshield.
 LCD monitor (fuel consumption, radio controls) located below the
instrument cluster.

Interior View




Instrument Cluster & LCD Monitor

5
Engine Compartment
 1.5 liter aluminum alloy gasoline engine.
High voltage inverter box with the Toyota Hybrid System logo on the
cover.

Orange colored high voltage power cables.

Toyota Hybrid System Logo on Inverter

Engine Compartment

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 Hybrid Component Locations & Descriptions
Component Location Description

12-Volt
Trunk, Driver Side Low voltage lead-acid battery that controls all
Auxiliary electrical equipment except electric motor
Battery generator, and inverter.
Hybrid  Trunk, Mounted to 274-Volt Nickel Metal Hydride (NiMH) battery
Vehicle (HV) Cross Member & pack consisting of 38 low voltage (7.2-volt)
Battery Pack Behind Rear Seat modules connected in series.
Power  Under Carriage & Orange colored power cables carry high
Cables Engine voltage Direct Current (DC) between the HV
Compartment battery pack and inverter. Also carries 3
phase Alternating Current (AC) between
inverter, motor, and generator.
Inverter  Engine Converts DC electricity from HV battery pack
Compartment to AC electricity that drives the electric motor.
Also, converts AC from electric generator and
motor (regenerative braking) to DC that
recharges the HV battery pack.
Gasoline  Engine Provides two functions: 1) powers vehicle; 2)
Engine Compartment powers generator to recharge the HV battery
pack. The engine is started and stopped
under control of the vehicle computer.
Electric  Engine 3 Phase AC permanent magnetic electric
Motor Compartment motor contained in the transaxle. Used to
power the vehicle.
Electric  Engine 3 Phase AC generator contained in the
Generator Compartment transaxle. Used to recharge the HV battery
pack.
Fuel Tank  Undercarriage, Fuel tank provides gasoline via a single fuel
and Fuel Passenger Side line to the engine. The fuel line is routed
Lines along passenger side under the floor pan.

Specifications
Gasoline Engine: 70 hp, 1.5 liter Aluminum Alloy Engine
Electric Motor: 44 hp, Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 274-Volt Sealed NiMH
Curb Weight: 2,765 lbs
Fuel Tank: 11.9 gals
Fuel Economy: 52/45 (City/Hwy)
Frame Material: Steel Unibody & Steel Body Panels

7




 
 



 

 A



A


12-Volt ⊕ Cable Power Cables
Section A-A Power Cable

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Gasoline-Electric Hybrid Vehicle Operation
The vehicle starts and becomes operational by turning the ignition key
to start just like any other typical automobile. 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 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, the gasoline engine may stop and start at any time while
the READY indicator is on.

• Never assume 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. The gasoline engine only.
3. A combination of both the electric motor and the gasoline
engine.

The vehicle computer determines the mode in which the vehicle

operates to improve fuel economy and reduce emissions. The driver
cannot manually select the mode.

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Instrument Cluster READY Indicator

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Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The Prius contains a high voltage, Hybrid Vehicle (HV) battery pack
and a low voltage auxiliary battery. The HV battery pack contains
non-spillable, sealed Nickel Metal Hydride (NiMH) battery modules
and the auxiliary battery is a typical automotive lead-acid type.

HV Battery Pack
• The HV battery pack is sealed in a metal case and is rigidly mounted to
the trunk floor pan cross member behind the rear seat. The metal case is
isolated from high voltage and concealed by a fabric liner in the trunk.

• The HV battery pack consists of 38 low voltage (7.2-Volt) NiMH

battery modules connected in series to produce approximately 274-
Volts. Each NiMH battery module is non-spillable and sealed in a
plastic case.

• The electrolyte used in the NiMH battery module is an alkaline of

potassium and sodium hydroxide. The electrolyte is absorbed into the
battery cell plates and will form a gel that will not normally leak, even
in a collision.

• In the unlikely event the battery pack is overcharged, the modules vent
gases directly outside the vehicle through a vent hose connected to each
NiMH battery module.

HV Battery Pack
Battery pack voltage 274-Volts
Number of NiMH battery modules in the pack 38
Battery pack weight 100 lbs
NiMH battery module voltage 7.2-Volts
NiMH battery module dimensions (inches) 11 x 3/4 x 4
NiMH Battery module weight 2.2 lbs

Components Powered by the HV Battery Pack

• Electric Motor • Inverter
• Electric Generator • Power Cables

HV Battery Pack Recycling

• The HV battery pack is recyclable. Contact the nearest Toyota dealer, or:
United States: (800) 331-4331 Canada: (888) Toyota-8

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Auxiliary Battery
• The Prius 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 trunk. It also contains a hose to

vent gases outside the vehicle if overcharged.

HV Battery Pack 12-Volt Auxiliary Battery

Metal Case
Top

NiMH Battery
Module

HV Battery Pack Case and NiMH Battery Module

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High Voltage Safety
The HV battery pack powers the high voltage electrical system with
direct current (DC) electricity. A positive and a negative power cable
are routed from the battery pack, under the vehicle floor pan, to the
inverter. Occupants in the vehicle and emergency responders are
separated from high voltage electricity by the following systems:

High Voltage Safety System

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

• The positive and negative 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 the HV battery
pack.

WARNING:
• Power remains in the high voltage electrical system for 5
minutes after the HV battery pack is shut off.
• Never touch, cut, or open any high voltage power cable or
high voltage component.

• Both power cables  are isolated from the metal chassis, so there is no
possibility of shock by 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 vehicle computer  will illuminate the
master warning light in the instrument cluster and the hybrid warning
light in the LCD display.

• The HV battery pack relays will automatically open to stop electricity

flow in a collision sufficient to activate the front SRS airbags.

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High Voltage Safety System – Vehicle Shut Off (READY off)

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

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SRS Airbags and Seat Belt Pretensioners
The Prius includes as standard equipment driver and passenger front
SRS airbags and front seat belt pretensioners. Side impact SRS
airbags contained in the front seats are optional equipment.

The SRS system is equipped with a back up source that powers the
SRS airbags up to 90 seconds after disconnecting the 12-Volt
auxiliary battery.

Airbag and Sensor Locations

• Two front SRS airbag sensors
are mounted in the engine
compartment for the driver  and passenger  airbags.

• The SRS computer , which also contains a sensor, is mounted on the

floor pan near the center console.

• Front seat pretensioners are mounted in the B-pillar .

• Optional side impact SRS airbags are contained in the front seats .
The sensors are mounted in the B-pillar .

SRS Airbag and Pretensioner Components

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Front Seat Airbag Components



Front Seat Belt Pretensioner Components




Front Seat Side Airbag Components

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

WARNING:
• Never assume the Prius 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.

Extrication
• Immobilize Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the P (park) position.

• Disable Vehicle (HV battery pack, SRS airbags, & gasoline fuel pump)
Turn the ignition key off, remove the ignition key, and place on
dash.
Disconnect 12-Volt auxiliary battery.

-OR (if the ignition key is inaccessible)-

Disconnect the 12-Volt auxiliary battery.

Remove the IGCT relay in the engine compartment as shown in the
illustration.

WARNING:
• After disabling the vehicle, power is maintained for 90 seconds in
the SRS system and 5 minutes in the high voltage electrical system.
• If either of the disabling steps above cannot be performed, proceed
with caution as there is no assurance that the high voltage
electrical system, SRS, or fuel pump are disabled.
• Never touch, cut, or open any orange high voltage power cable or
high voltage component.

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 Chock Wheels Set Parking Brake

Move Shift Lever To Park Remote Trunk Opener (Driver Side)

12-Volt Auxiliary Battery Cover Remote Hood Release

IGCT Relay

Hood Latch Release IGCT Relay Location

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Emergency Response (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 tank.

• Access Patients
Glass Removal
Use normal glass removal procedures as required.

Door Removal/Displacement
Doors can be removed by conventional rescue tools- hand,
electric, and hydraulic.
In certain situations, it may be easier to pry back the body to
expose and unbolt the hinges.

Dash Displacement
Displace the dash by using a conventional dash roll, Modified
Dash Roll, or jacking the dash.

Roof Removal
The roof may be removed as there are no SRS airbag devices
above the door line.

Rescue Lift Air Bags

Responders should not place rescue lift airbags under the high
voltage power cables, exhaust system, or fuel tank.

Steering and Seat Controls

Tilt steering and seat controls are shown in the illustration.

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 Cribbing Points

Tilt Steering Control Front Seat Controls

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Emergency Response (Continued)
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.

• 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 until the fire has
been knocked down and overhaul operations have commenced.

• Fire in the HV Battery Pack

Should a fire occur in the NiMH HV battery pack, the incident
commander will have to decide whether to pursue an offensive or
defensive attack.

WARNING:
• Potassium hydroxide and sodium hydroxide are key
ingredients in the NiMH battery module electrolyte.
• The modules are contained within a metal case and access
is limited to a small opening on the top.
• The cover should Never be breached or removed under any
circumstances, including fire. Doing so may result in severe
electrical burns, shock or electrocution.

When allowed to burn themselves out, the Prius NiMH battery

modules burn rapidly and can quickly be reduced to ashes except for
the metal alloy cell plates.

Offensive Fire Attack

Flooding the HV battery pack, located in the trunk, with copious
amounts of water at a safe distance will effectively control the HV
battery pack fire by cooling the adjacent NiMH battery modules to a
point below their ignition temperature. The remaining modules on
fire, if not extinguished by the water, will burn themselves out.

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 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 NiMH battery modules 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.

Overhaul
During overhaul, if not already done, immobilize and disable the vehicle.
See illustrations on page 18.

• Immobilize Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the P (park) position.

• Disable Vehicle (HV battery pack, SRS airbags, & gasoline fuel pump)
Turn the ignition key off, remove the ignition key, and place on
dash.
Disconnect 12-Volt auxiliary battery.

-OR (if the ignition key is inaccessible)-

Disconnect the 12-Volt auxiliary battery.

Remove the IGCT relay in the engine compartment.

WARNING:
• After disabling the vehicle, power is maintained for 90 seconds
in the SRS system and 5 minutes in the high voltage electrical
system.
• If either of the disabling steps above cannot be performed,
proceed with caution as there is no assurance that the high
voltage electrical system, SRS, or fuel pump are disabled.
• Never touch, cut, or open any orange high voltage power cable
or high voltage component.

Recovery/Recycling NiMH HV Battery Pack

Clean up of the HV battery pack can be accomplished by the vehicle recovery
crew without further concern from runoff or spill. For information regarding
recycling of the HV battery pack, contact the nearest Toyota dealer, or:

United States: (800) 331-4331 Canada: (888) Toyota-8

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Emergency Response (Continued)
Spills
The Prius contains the same common automotive fluids used in other Toyota
vehicles, with the exception of NiMH electrolyte used in HV battery pack.
The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is
damaging to human tissues. The electrolyte, however, is absorbed in the
cell plates and will not normally spill or leak out even if a battery module is
cracked. A catastrophic crash that would breach both the metal battery pack
case and the plastic battery module would be a rare occurrence.

Similar to using baking soda to neutralize a lead-acid battery electrolyte

spill, a dilute boric acid solution or vinegar is used to neutralize a NiMH
battery electrolyte spill.

During an emergency, Toyota Material Safety Data Sheets (MSDS) may be

requested by contacting:
United States: CHEMTREC at (800) 424-9300
Canada: CANUTEC at *666 or (613) 996-6666 (collect)

• Handle NiMH Electrolyte Spills Using The Following Personal

Protective Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are not
acceptable for alkaline spills.
Rubber, latex or Nitrile gloves.
Apron suitable for alkaline.
Rubber boots.

• Neutralize NiMH Electrolyte

Use a boric acid solution or vinegar.
Boric acid solution - 800 grams boric acid to 20 liters water or 5.5
ounces boric acid to 1 gallon of water.

First Aid
Emergency responders may not be familiar with a NiMH 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 during an exposure.

WARNING:
The NIMH battery electrolyte is a caustic alkaline (pH 13.5) that is
damaging to human tissue.

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• Wear Personal Protective Equipment (PPE)
Splash shield or safety goggles. Fold down helmet shields are not
acceptable for acid or alkaline spills.
Rubber, latex or Nitrile gloves.
Apron suitable for alkaline.
Rubber boots.

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

• Inhalation Non-Fire Situations

No toxic gases are emitted under normal conditions.

• Inhalation Fire Situations

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

• Ingestion
Do not induce vomiting.
Allow patient to drink large quantities of water to dilute electrolyte
(Never give water to an unconscious person).
If vomiting occurs spontaneously, keep patients head lowered and
forward to reduce the risk of aspiration.
Transport to the nearest emergency medical care facility.

Submersion
To safely handle a Prius that is fully or partially submerged in water, disable
the high voltage electrical system and SRS airbags.

• Remove vehicle from the water.

• Drain water from the vehicle if possible.

• Follow the extrication and vehicle disabling procedure (page 17).

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Roadside Assistance
No special or unusual handling is necessary for Prius roadside
assistance. The vehicle may be handled like other Toyota vehicles
and the following information may be useful for guidance.

Toyota Roadside Assistance is available during the basic warranty period

by contacting:

United States: (877) 304-6495 Canada: (888) TOYOTA-8

Towing
The Prius is a front wheel drive vehicle. Tow with the front wheels off the
ground.

• To shift the vehicle to neutral, turn the ignition switch on, press the
brake, and while pressing the shift lever button, move the lever to the N
(neutral) position.

• If the shift lever cannot be moved out of P (park), a shift lock release is
provided under the steering column cover as shown in the illustration.

Spare Tire
The spare tire, jack, and tools are provided in the trunk as shown in the
illustration. The spare tire is for temporary use only (do not exceed 50 mph).

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 turning the
ignition key to start.

• The 12-Volt auxiliary battery is located in the trunk. Follow the

numbered sequence to connect the jumper cables as shown in the
illustration.

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

Alarm & Immobilizer

The vehicle comes standard with a keyless remote alarm and a coded key
immobilizer system.

• The vehicle may only be started with a learned immobilizer coded key.

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• To disable the alarm use the unlock button on the keyless remote,
unlock either front door lock with the key, or turn the ignition switch on.

Remove Shift Lock Release Cover Push In Shift Lock Release

Spare Tire and Tool Location Access 12-Volt Auxiliary Battery In

Trunk

12-Volt Battery Jumper Cable Connections

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© 2001 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

Printed in the United States of America

TMS M/N 00400-ERG02-0U

REV A (1/15/02)