Hybrid

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

Why is the hybrid vehicle necessary?
(ppmv)
CO2 Concentration
600
500
400
300
Increase Automobile
market
1970
2006
260
1200
1400
1600
1800
Expanding Energy
Consumption
Low fuel consumption and low CO2 emission

vehicle is required
2000
2100

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
CNG
DPR
Common-rail
Alternative
Energy
Diesel
Engine
D-4
Lean Burn
EV
VVT-i
Gasoline
Engine
Electric
Vehicle

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

Parallel Hybrid System
The wheels are driven by both the engine and the
motor

THS (TOYOTA Hybrid System)
Strong points of both series/parallel systems realized
in one system

Hybrid system comparison
Fuel Economy Improvement

System
Idling
Stop
Energy
Recovery
High-efficiency
Operation Control
Total
Efficiency
Acceleration
Continuous
High Output
Series
Parallel
THS
(Series /
Parallel)
: Excellent
Driving Performance
: Superior
: Somewhat Unfavorable

Other Hybrid Vehicle
Fuel cell hybrid vehicle
PRIUS
(THS)
FCHV
(Fuel Cell Hybrid Vehicle)
Engine
Battery
Fuel Cell
Power
Control
Unit
Motor
10
Battery
Power
Control
Unit
Motor

Concept
Low Fuel
Consumption
11
Higher
Power

Hybrid vehicle realizes low fuel consumption and
higher power
PRIUS
(NHW20)
PRIUS
(NHW11)
(km/L)
Japanese 10 15
Mode Fuel Efficiency
Good Fuel
Economy
Corolla
(1.3L)
Corolla
(1.5L)
Tradeoff between performance

and fuel economy in
conventional vehicle
CAMRY
(2.4L)
Good Acceleration
12
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
13

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
14

Number of Hybrid Vehicles for Sale
1997
2001
2003
2004
2006
2007
600,000
PRIUS
(NHW11)
Cumulative Sales
500,000
400,000
ESTIMA*
PRIUS
(NHW20)
RX400h
300,000
200,000
GS450h
LS600h
CROWN*
ALPHARD*
100,000
HIGHLANDER
CAMRY
1997
15
2001
2003
2004
2006
2007
*: Only for Japanese market
THS II
(TOYOTA Hybrid System)
PRIUS [NHW20]
16

THS II Components
HV Battery
Generator (MG1)
Engine
Powerdividing
Device
17
Inverter
Motor (MG2)

System Diagram
Shift Position
Sensor
(Shift, Select)
Click here to see

operation of
shift lever
Hybrid Transaxle
MG1
Electric A/C
Compressor
MG2
Accelerator
Pedal Position
Sensor
HV
ECU
EV Mode
Switch
Engine
ECU
Inverter
A/C
Inverter
Boost
Converter
DC DC
Converter
Engine
Brake
Actuator
Speed
Sensors
18
SMR1, 2 and 3
Skid Control
ECU
CAN
DLC3
Battery
ECU
HV
Battery
Auxiliary
Battery

Location
Inverter
Engine
Hybrid Transaxle
Generator (MG1)
Motor (MG2)
Power-dividing Mechanism
19
HV Battery

Outline
Compression from conventional vehicle
Item
Power
Source
Transmission
Brake
Battery
20
Power
Train
Control
Conventional
Vehicle
Engine
THS II
Engine
Motor
Generator
A/T
M/T
Hydraulic Brake
12V Battery
Engine ECU
Power Splitting
Device
Hydraulic
Brake
Regenerative Brake
12V
Battery
201.6V Battery
HV
ECU
Engine ECU
Inverter
Note for THS II

Motor
drive is possible
(Engine OFF)
Engine motive force is
divided for drive and
electric generation
Divide
the engine, motor

and generator power
Function as CVT
Cooperative control
between hydraulic and
regenerative brake
High-voltage supply for
motor drive
Controls the engine,
motor and generator

Outline
System operation
21
Start-off
Normal
Driving
Electric
motor only
Motor and
Engine
Acceleration
Deceleration
Motor and Engine

(additional power
drawn from battery)
Battery
charging
Stop
Engine
automatically
shuts off

Outline
System operation
22
Vehicle Stopped
Start-off,
Low Load Driving,
Reverse
Normal Driving
High Load Driving
Deceleration
Vehicle Stopped
(Charging)

1NZ-FXE Engine
1.5 liter, In-line 4-cylinder, 16-valve DOHC, gasoline
engine
1NZ-FXE
X = Atkinson Cycle
23

Hybrid Transaxle
Includes AC 500V motor, generator and power-dividing
mechanism
Uses a continuously variable transmission mechanism
to achieve smooth and quiet operations
MG1
MG2
Power-dividing
Mechanism
24

HV Battery
Full sealed nickel metal hydride (Ni-MH) battery
DC 201.6V
Located behind the rear seat
25

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
26

Brake System
ECB (Electrically Controlled Brake)
Hydraulic brake pressure is controlled by electrical
signal and cooperate regenerative brake
Drivers Demand
Vehicle Condition
27
Skid
Control
ECU
Hydraulic
Brake Control
HV ECU
Regenerative
Brake Control

Steering System
EPS (Electric Power Steering) is used
EPS ECU
EPS Motor
28

Air Conditioning System
Compact, high-performance scroll compressor driven
by motor
Electric Inverter Compressor
29

Multi Display
Energy Monitor
30

Multi Display
Fuel consumption indicator
31

Auxiliary Battery (12V)
Auxiliary battery supplies power to headlights, audio,
and all ECUs
Sealed-type battery is used
Auxiliary
Battery
32

Power Cable
Orange-colored wire harness / connector
High-voltage circuit
High-voltage Wire Harness
33

Service Plug
Shut off the high-voltage circuit
Service Plug
34
Caution: Wear insulated gloves when disconnecting / connecting the

service plug to prevent against electrical shock
Engine
35
Engine
Atkinson Cycle
The X of the 1NZ-FXE indicates the use of the
Atkinson cycle, the principle applied for this vehicles
engine
Atkinson cycle
High thermal efficiency
1NZ-FXE (PRIUS)
36
Engine
Overview
Atkinson cycle
Compression Stroke < Expansion Stroke

High thermal efficiency
37
Compression
Expansion
Engine
Overview
Atkinson cycle
Depending on the driving condition, the cylinder
volume is varied by VVT-i
Valve Timing (Intake Valve)
Cylinder Volume
TDC
105
90
105
VVT-i
Operation
72
72
38
BDC
Engine
Overview
Specifications
Item
1NZ-FXE (04 PRIUS)
1NZ-FE (Corolla)
No. of Cylinders & Arrangement
4-Cylinder, in-line
Valve Mechanism
16-Valve DOHC,
Chain Drive, VVT-I
1497 (91.3)
75.0 x 84.7 (2.95 x 3.33)
13.0
10.5
Displacement
cm3 (cu. in.)
Bore x Stroke
mm (in.)
Compression Ratio
Max. Output
EEC (-W, -Q)
57 kW @ 5000 rpm
78 kW @ 6000 rpm
Max. Torque
EEC (-W, -Q)
115 Nm@ 4200 rpm
145 Nm@ 4200 rpm
Open
18 - -15 BTDC
42 - -2 BTDC
Close
72 - 105 ABDC
10 - 50 ABDC
Open
34 BBDC
42 BBDC
Close
2 ATDC
STEP IV
STEP III
Valve
Timing
Intake
Exhaust
Emission Regulation
42
Engine
Overview
Engine compartment
Drive belt simply layout
TOYOTA Genuine
Super LLC
43
Radiators (for engine and

inverter) are one piece
Engine
Overview
Interior
Non-contact type accelerator

pedal position sensor
44
32-bit engine ECU with

CAN communication
Engine
Overview
Under floor
Plastic Type Fuel
Tank (-W, -Q)
45
Engine
Engine Proper
Piston
Lightweight and low friction
Shape is changed
to weight reduction
Piston skirt portion is

reduced to friction reduction
223g (Corolla)
194g (Prius)
Prius
New resin coat to

friction reduction
46
Corolla
Engine
Engine Proper
Piston Ring
Lower tension and thinner piston ring is used for
friction reduction
Piston
Ring
Top
Ring
Second
Ring
Cross section
Tension
Thickness
Others
Inner Bevel Type
4.2 N
3N
1.2 mm (0.047 in.)
0.8 mm (0.031 in.)
PVD coat is used to

improve wear
resistance
Taper Type
3.3 N
3N
1.2 mm (0.047 in.)
1.0 mm (0.039 in.)
Steel material is
used to improve
wear resistance
2.0 mm (0.079 in.)
1.5 mm (0.059 in.)
2 Piece Type
17 N
8N
Oil Ring
47
Corolla
Prius
Engine
Throttle Body (ETCS-i)
Prius uses linkless electronic throttle control
Amount that
accelerator is
depressed does not
match throttle
opening in THS II
system.
48
Engine
The throttle valve is driven by the DC motor.
The throttle valve initial opening angle 3

to prevent valve from sticking when cold.
Throttle Control Motor
Throttle Position Sensor
49
Return spring
Throttle Valve
Engine
Throttle valve is controlled by the HV ECU.
ETCS-i also controls the cruise control system.
50
Engine
Cooling System
Radiators (for engine and inverter) are one piece
Radiator
(for engine)
Drain Plug
(for engine)
Radiator
(for Inverter)
51
Front
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
the tank
Before engine start
Hot coolant to
cylinder head
52
Amount of
adhesion of
fuel is
reduced after
engine start
Heated
Engine
System Diagram
Heater Core
Engine Coolant
Temp. Sensor
Cylinder Head
Water
Pump
Water
Valve
Coolant Heat Storage

Tank Outlet Temp. Sensor
Water
Pump
Coolant Heat
Storage Water Pump
Cylinder
Block
Radiator
53
Coolant
Heat
Storage
Tank
ECM
Water Pump
Relay
Engine
Components
Engine Coolant
Temp. Sensor
to / from
heater core
Water Pump
(for Heater)
Water
Valve
Coolant Heat
Storage
Water Pump
Coolant Heat
Storage Tank
54
Coolant Heat Storage

Tank Outlet Temp. Sensor
Reverse Side
Engine
Coolant Heat Storage Tank
This tank stores hot coolant and keeps it warm
Coolant Heat
Storage Tank
Coolant Heat
Storage
Tank Outlet
Temp. Sensor
Front
Drain Plug
55
Caution: The coolant in this tank is hot even if

engine and radiator are cold
Engine
Coolant flow at preheat operation
from Engine
Vacuum
Front
Drain
Plug
Cross-section
56
to Water Valve
(Cylinder Head)
Engine
Coolant Heat Storage Water Pump
Supplies hot coolant to cylinder head
Stores hot coolant in coolant heat storage tank
from Engine
Centrifugal
Centrifugal Pump
Pump
DC
DC Brush
Brush Motor
Motor
The flow during
pump operating
to Coolant Heat
Storage Tank
57
Engine
Coolant Heat Storage Water Pump
Specifications
Pump Type
Centrifugal Pump
Motor Type
DC Brush Motor
Preheat Operation (14V)
Storage Operation (12V)
58
Flow Volume
(per minute)
23.5 liters
(24.84 US qts., 20.68 Imp qts.)
Discharge
Pressure
32 kPa
(4.64 psi, 0.326 kgf/cm)
Flow Volume
(per minute)
21 liters
(22.19 US qts., 18.48 Imp qts.)
Discharge
Pressure
25.5 kPa
(3.70 psi, 0.260 kgf/cm)
Engine
Water Valve
This valve switches coolant passage among engine,
coolant heat storage tank and heater core
Coolant Heat
Storage Tank
Heater
Core
59
Rotary
Valve
Coolant Heat
Storage Tank
Motor
Engine
Heater
Core
Engine
Engine
Water Valve
Rotary valve operation
A
Heater
B
Tank
Heater
C
Tank Heater
Tank
Rotary
Valve
Position
Engine
operation
Storage operation
System
(after power switch
Operation OFF)
Power switch OFF
Engine
Engine
Preheat
60
Storage
operation
(during engine
running)
Engine
running (w/o
storage operation)
Engine
Operation
IG-ON
READY
OFF
HV ECU
ON
Engine ECU
(ECM)
Water Pump
Engine
System
Operation
61
ON
ON
ON
Stopped
Starting
Preheat
Operation
Storage
Operation
Storage
Operation
Engine
Operation
Preheat operation (before engine start)
Heater
Core
Heated
Cylinder Head
Water
Pump
Cylinder
Block
Water
Valve
Water
Pump
ON
62
Engine
Confidential

Operation
Start conditions
Preheat Operation Start Conditions
AND
63
Engine
coolant temp. is 40 C (104 F) or less
Engine
coolant temp. is 0 C (32 F) or more
Engine
is stopped
Engine
Confidential

Operation
Stop conditions
Preheat Operation Stop Conditions
No.1
cylinder intake port temp. reaches the target temp.
Coolant
flow volume exceeds 3 liter (10 sec. elapsed)
OR
Tank
outlet temp. is below the before operation
Engine
64
starting (when engine power is necessary)
Engine
Operation
Engine running (w/o storage operation)
Heater
Core
Cylinder Head
Water
Pump
Cylinder
Block
Water
Valve
Water
Pump
OF
F
65
Engine
Operation
Storage operation (during engine running)
Heater
Core
Cylinder Head
Water
Pump
Cylinder
Block
Water
Valve
Water
Pump
OF
F
66
Hot coolant
is stored
Engine
Confidential

Operation
Operation chart
Tank coolant temp. is
90 C (194 F) or more
Engine
Starting
Warm-up
Storage is
Completed
Others
Meets start
conditions
Meets stop
conditions

[Max.: 4 times]
67
Engine
Confidential

Operation
Start conditions
Storage Operation Start Conditions
Engine
AND
The
number of times of storage operation during 1 trip is

less than 4 times
Engine
68
coolant temp. is higher than the specified value
is running
Engine
Confidential

Operation
Stop conditions
Storage Operation Stop Conditions
Engine
Storage operation
is discontinued
Engine
Continues to the next

storage operation
coolant temp. is lower than

the specified value
OR
Tank
is stopped
coolant temp. reaches 90 C

(194 F) or more
69
Storage operation
is completed
Engine
Diagnosis
DTCs for Coolant Heat Storage System
DTC
No.
70
Detection Item
DTC
No.
Detection Item
P1115
Coolant temp. sensor circuit for

coolant heat storage system
P1122
Water valve position sensor circuit

low
P1116
Coolant temp. sensor circuit stuck

for coolant heat storage system
P1123

high
P1117
Coolant temp. sensor circuit low for

coolant heat storage system
P1150
Coolant Path Clog Up for Coolant

Heat Storage System
P1118
Coolant temp. sensor circuit high

for coolant heat storage system
P1151
P1120
P2601
Coolant pump control circuit

range / performance
P1121

stuck
P2610
ECM / PCM internal engine off timer

performance
Engine
Service Point
Water pump is operated 5 hours after system OFF to
detect system malfunction
Coolant temp. is
not changed
Preheat
THW
Time
50 C (122 F)* or less

(Continues two trips)
5 hours after
system OFF: Water
pump is operated 7
sec. to detect
system malfunction
Judgment
P1151: Outlet temp. difference is 25 C or more from coolant recovery
P2601: Outlet temp. is no change from water pump ON
71
*: The temp. is changed in accordance with the

engine temp. before preheat operation
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
72
Engine
Service Point
Coolant Replacement
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
73
Engine
Service Point
Coolant Replacement
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
74
Engine
Fuel System
(Fuel Delivery Pipe)
Pulsation damper eliminated
75
Engine
Fuel System
(Vapor reducing fuel tank)
Reduce the amount of
fuel vapors released
when vehicle is
parked.
76
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 10C.
Click!
zoom
77
Engine
Fuel System
VSV (for EVAP)

Fuel Inlet
VSV (for Purge Flow

Switching Valve)
Vapor
Pressure
Sensor
Charcoal Canister
Fuel Pump
And
Sender Gauge
VSV (for Canister

Closed Valve)
79
Bladder Tank
Sub Tank
Engine
Fuel System
Fuel Sender Gauge
Sub-tank is installed
inside the fuel tank,
inside which a fuel
pump and sender
gauge are attached.
Sub-tank
Fuel Sender Gauge
80
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
81
Engine
Fuel System
ORVR (Onboard Refueling Vapor Recovery)
Intake Air Chamber
Air Cleaner
VSV (for EVAP)

Fuel Inlet
VSV (for Purge Flow

Switching Valve)
Vapor
Pressure
Sensor
Charcoal Canister
Vapor
Fresh Air Line
Trap Canister
Fuel Pump
And
Sender Gauge
Charcoal
Canister Filter
VSV (for Canister

Closed Valve)
82
Bladder Tank
Sub Tank
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
83
Engine
HV Immobiliser System
Cannot be started without registered key
Transponder
Chip
ID
Code
Key
Transponder
Key ECU
Key Slot
Smart
ECU
84
Engine ECU
Transponder Key
Amplifier and Coil
HV
ECU
Injector
Spark
Plug
Power
Supply
Control
ECU
MG1, 2
Hybrid Transaxle
85
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
86
Hybrid Transaxle
Overview
P112 type
Planetary Gears
MG2
87
Chain-drive
Sprocket
MG1
Hybrid Transaxle
Overview
P112 type
Counter Drive
Gear
Chain-driven
Sprocket
Counterdriven Gear
Final Drive
Pinion Gear
Final Ring
Gear
Differential
Mechanism
88
Reduction
Mechanism
Hybrid Transaxle
MG1 / MG2
Compact and lightweight, highly efficient AC500V
motor generator
MG1
89
MG2
Hybrid Transaxle
MG1
Main operations Generator
When engine starting Starter
Stator Coil
Rotor
90
Speed Sensor
MG1
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
91
Speed Sensor
Rotor
MG2
Hybrid Transaxle
Speed Sensor (Resolver)
Detects position, speed and direction of MG1 / MG2
rotors
Speed Sensor
(for MG1)
92
Speed Sensor
(for MG2)
Hybrid Transaxle
Transaxle Damper
Installed at location of conventional clutch
Reduces shock which occurs when kinetic energy is
transmitted
93
Hybrid Transaxle
Cooling System
Cooling circuit is used for both MG1 / MG2
Separate cooling system from engine
Reservoir
Reservoir Tank
Pump
MG1 / 2
Radiator
Radiator
Inverter
94
Electric
Water Pump
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
95
Inverter Assembly
96
Inverter Assembly
Components
Inverter
DC AC high voltage
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
97
Inverter Assembly
Components
Inverter Assembly
Variablevoltage
System
Inverter
MG2
HV Battery
A/C
Inverter
DC - DC
Converter
98
MG1
Inverter Assembly
DC 201.6V Max. DC 500V conversion
Max. DC 500V

DC 201.6V
DC 201.6V
Inverter Assembly
Variablevoltage System
IPM (IGBT)
Reactor
MG1
DC500V
Inverter
(IPM)
AC500V
MG2
HV Battery
: Discharge
99
: Charge
Inverter Assembly
Inverter Operation
Motor control
Motor Torque is controlled
by the current value
High
Torque
Low
Torque
10
Motor Speed is controlled by

the frequency
High
Speed
Low
Speed
Inverter Assembly
DC DC Converter
DC201V DC 12V
Inverter Assembly
HV Battery
Variablevoltage
System
MG1
Inverter
MG2
DC DC Converter
DC 201.6V
DC
AC
AC 201.6V
AC 12V
AC
DC
DC 12V
Auxiliary
Battery
10
Inverter Assembly
A/C inverter
DC201.6V AC201.6V conversion
A/C ECU
Target
Compressor
Speed
DC 201.6V
HV ECU
AC 201.6V
A/C Inverter
HV Battery
Inverter Assembly
10
DC 201.6V
AC 201.6V
Electric
Inverter
Compressor
Inverter Assembly
Cooling System
Cooling circuit is used for inverter assembly
Separate cooling system from engine
Reservoir
Reservoir Tank
Pump
MG1 / 2
Radiator
Radiator
Inverter
10
Electric
Water Pump
HV Battery Assembly
10
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
10
HV Battery
(DC 201.6V)
Auxiliary Battery
(DC 12V)
HV Battery Assembly
Components
Module
Current
Sensor
SMR3
SMR2
Resister
10
Battery ECU
SMR1
Service
Plug
Connector
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)
10
HV Battery Assembly
Battery ECU
Maintains control of HV battery SOC (State of charge)
Ensures battery capability
Battery ECU
Battery
Cooling Fan
Relay
SOC
SOC
Control
Control
HV
HV Battery
Battery
Condition
Condition Detection
Detection
Electrical
Electrical Leakage
Leakage Detection
Detection
for
for High-voltage
High-voltage System
System
Battery
Cooling Fan
Controller
Voltage x 14
+
Battery
Cooling Fan
Motor
10
Service
Plug
Current
Sensor
CAN
Cooling
Cooling Fan
Fan
Control
Control
Diagnosis
Diagnosis Function
Function
for
for HV
HV Battery
Battery
HV ECU
Engine ECU
A/C ECU
Temp. x 4
Temp. Sensors
(Thermistor)
HV Battery
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
10
HV Battery Assembly
SOC Control
When the SOC is dropped, battery ECU sends the
Charge Request signal to HV ECU
Battery ECU
SOC
SOC
Charge
Request
HV ECU
Power
Request
Engine
ECU
Control
Voltage
(SOC)
Charging
HV Battery
11
Charge
MG1
Drive
Engine
HV Battery Assembly
SMR (System Main Relay)
Turns ON / OFF the high-voltage circuit
SMR3
SMR1
SMR2
11
HV Battery Assembly
SMR
Shutdown control
READY OFF
11
At Collision
Interlock Switch OFF

(Service plug grip disconnection, Inverter cover open)
HV Battery Assembly
Service Plug
Shut off the high voltage circuit manually
Service Plug
11
HV Battery Assembly
Auxiliary Battery
Auxiliary battery supplies power to headlights, audio,
and all ECUs
Auxiliary
Battery
11
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
11
HV Battery Assembly
Auxiliary Battery
Jump Start Terminal
+ terminal of auxiliary battery for jump start is
used
Jump Start
Terminal
11
THS II Operation
11
THS II Operation
Components
HV Battery
Generator (MG1)
Engine
Power-dividing
Device
Differential
Mechanism
11
Inverter
Motor (MG2)
THS II Operation
Power-dividing Mechanism (Planetary Gears)
Sun gear: MG1
Planetary Carrier: Engine
Ring Gear: MG2 (Front Wheel)
Engine
Chain
11
MG2
MG1
To Front Wheel
Power-dividing
Mechanism
THS II Operation
Engine Starting and Idling
Vehicle
Speed
Click!
animasi
12
Click!
Movie
THS II Operation
Vehicle Starting Off
Vehicle
Speed
Click!
animasi
12
Click!
Movie
THS II Operation
Accelerating Under Low Load (Light Throttle)
Request more power, MG1 starts engine
Vehicle
Speed
Click!
animasi
12
Click!
Movie
THS II Operation
Accelerating Under Heavy Load (Full Throttle)
Vehicle
Speed
Click!
animasi
12
Click!
Movie
THS II Operation
Decelerating
Vehicle
Speed
Click!
animasi
12
Click!
Movie
THS II Operation
Driving in Reverse
Vehicle
Speed
Click!
animasi
12
Click!
Movie
THS II Operation
THS-II Control
Motive Force Suppression Control
When wheel slipping is detected, the HV ECU
controls the MG2 motive force and applies the
hydraulic brake force
Each
wheel
Speed
Sensors
Slipping
Skid
Control
ECU
HV ECU
High Speed
Traction
Control
Speed
Sensor
MG2
Brake
Force
12
Inverter
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
Combination
Meter
EV Mode
Indicator
Light
12
Battery ECU
SOC Condition
Battery Temp.
Gateway
ECU
HV ECU
Accelerator Pedal
Position Sensor
Speed
Sensors
Engine ECU
EV
Mode
Switch
Skid Control
ECU
Drive
HV
Battery
Inverter
THS II Operation
THS-II Control
EV Mode Switch is momentary type
EV Mode
Switch
LHD Model
12
THS II Operation
THS-II Control
Operation conditions
Push
EV Mode
Normal
EV
EV mode
mode canceling
canceling conditions
conditions
or
12
EV
EV mode
mode switch
switch is
is pushed
pushed
HV
battery
SOC
drops
HV battery SOC drops
HV
HV battery
battery temp.
temp. is
is low
low or
or high
high
Engine
Engine is
is warming
warming up
up
Vehicle
speed
exceeds
Vehicle speed exceeds the
the
specified
speed
specified speed
The
The accelerator
accelerator pedal
pedal position
position
angle
exceeds
the
specified
angle exceeds the specified value
value
ECB
(Electronically Controlled Brake)
13

General
The total brake force provided by both hydraulic and
regenerative brakes matches the braking power
required
Regenerative Brake
13
Hydraulic Brake

ECB Operation
Hydraulic brake pressure is generated electrically
(brake by wire)
ECB Vehicle
Brake Force
Generation
Sensor
Conventional Vehicle
Brake Force
Generation
13
Skid
Control
ECU
Control
13

Combination Meter
READY light indicates that the vehicle is ready to drive
Ready Light
13

Multi Display
Energy monitor shows the energy flow
13

Multi Display
Warning display
Warning marks
Discharge
Warning
Hybrid
System
Abnormal
13
High Engine
Coolant
Temperature
Warning
Oil
Pressure
Warning
HV
Battery
Warning
EPS
Warning
Automatic
Headlight
Leveling System
Warning

Multi Display
Warning message
13
Other Systems
13
Other Systems
General
Engine is operated intermittently, so power steering
and A/C compressor uses electric power
EPS (Electric Power Steering)
13
Electric Inverter Compressor
Other Systems
EPS (Electric Power Steering)
Column assist type EPS is used
EPS ECU
DC Motor
(12V)
Reduction
Mechanism
14
Torque Sensor
Column Assist Type EPS
Other Systems
Air Conditioning
Service Point
Dont use the compressor oil other than ND11
-O
ND
IL
11
ND-OIL8
14
Service Point
14
Service Point
Inspection Mode
In the inspection mode, engine is continuously
operated (P range) and motor TRC is turned off
Mode
Vehicle Condition
Inspection Mode- Keeps engine

2WD Inspection
running (P range)
(Inspection Mod1) Motor TRC is OFF
Inspection Mode2WD ChassisMotor TRC is OFF

Dynamo
(Inspection Mod2)
14
Purpose
Exhaust
gas test
Engine adjusting
Speedometer test
Speedometer test
(chassis
dynamometer)
Transferring
Procedure
Manual
procedure
Intelligent tester
(Active Test)
Intelligent tester
(Active Test)
Note: Other hybrid vehicle has several types of inspection mode.

For derails, please refer to the repair manual.
Service Point
Inspection Mode
Manual procedure
within 60 seconds
with brake
OFF
IG-ON
Accelerator
Pedal
Depress
twice
14
Depress
twice
Depress
twice
IG-ON
READY
Change the power mode to OFF inspection mode is canceled
Service Point
All high-voltage wire harness and connectors are
colored orange
14
Service Point
Use a megohmmeter to measure the insulation
resistance (Standard: 2 10 M)
Megohmmeter
Basically use the 500V range

Notice: If you use the 1000V range, it
causes the breakdown of the parts
14
It cannot check the

insulation resistance
correctly by the TOYOTA
Electrical Tester
Service Point
Risk of electric shock
Case
14
Condition
Risk of Electric Shock
Touch the high-voltage + side
No risk
Touch the body (high-voltage - side)

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

there is a electrical leakage
Possibility of
electric shock
Touch the high-voltage + and - side
Electric shock !
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)
14
Service Point
Safety Precautions
1.Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH
DURING OPERATION" sign to notify other engineers
14
Service Point
Safety Precautions
5.Check the insulated gloves
Not cracked, ruptured, torn,
or damaged
Not wet
15
Service Point
Safety Precautions
6.Remove the service plug
Carr
your y in
pock
et
Service Plug
Remove before servicing
15
Service Point
Safety Precautions
8.Measure the inverter terminal voltage (0V check)
0V
Between
3 phases
3 phases and
body ground
0V
15
Inverter Assembly
Service Point
Safety Precautions
During servicing the high voltage area
Insulate the tools by vinyl tape
Insulated Vinyl Tape
15
Service Point
Safety Precautions
Insulate the disconnected high-voltage connector
with insulated vinyl tape
Insulated Vinyl Tape
15
Service Point
Safety Precautions
Non-reusable nut is used to the installation of high
voltage line
New
Example of use
Wire x SMR
Used
15
Nonreusable
Junction Block x Module
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
15
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
15
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
15
Service Point
Response When The HV Battery (201.6V) Runs Out
Charge the HV Battery using THS Charger
THS
Charger
THS Charger
15
Note: THS charger is the recommended tool
Service Point
Battery Pack Removal / Installation
If the HV battery electrolyte leaks, dont touch it
Neutralize
battery
electrolyte
Boric Acid Solution
Dont touch the battery

electrolyte !
Boric Acid
(800 g)
16
Water
(20 liters)
Service Point
Towing
16
Notice: If there is a electrical leakage, motor regenerates

the electricity by wheel rotation

Hybrid

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Contents

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

Low fuel consumption and low CO2 emission

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

Fuel Economy Improvement

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

Tradeoff between performance

0 100 km/h Acceleration (sec.)

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

What is the Hybrid Vehicle?

*: Only for Japanese market

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

Click here to see

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

Note for THS II

the engine, motor

THS II (TOYOTA Hybrid System)

Motor and Engine

THS II (TOYOTA Hybrid System)

High Load Driving

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

Electric Inverter Compressor

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

THS II (TOYOTA Hybrid System)

High-voltage Wire Harness

THS II (TOYOTA Hybrid System)

Caution: Wear insulated gloves when disconnecting / connecting the

Compression Stroke < Expansion Stroke

Valve Timing (Intake Valve)

1NZ-FXE (04 PRIUS)

No. of Cylinders & Arrangement

75.0 x 84.7 (2.95 x 3.33)

cm3 (cu. in.)

EEC (-W, -Q)

EEC (-W, -Q)

115 Nm@ 4200 rpm

145 Nm@ 4200 rpm

Drive belt simply layout

Radiators (for engine and

Non-contact type accelerator