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1071 Toyota Hybrid System
WelcomeWelcome
Course 071 Toyota Hybrid System
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2071 Toyota Hybrid System
Hybrid System OverviewTransaxle Operation
Day One
Day Two
Day Three
High Voltage SystemEngine
Brake System
Electric Power Steeringir !onditioning"#ltiplex !omm#nicationHybrid $eneral "aintenance
Course Agenda
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071 Toyota Hybrid System
Wor!sheet O"er"iew
Wor!sheet 1# Hybrid Wal!arounds
Wor!sheet 2# Data $ist Test Dri"e
%$D 1# Transa&le Assembly 'arts %denti(ication
%$D 2# %n"erter Sa(ety
%$D # )attery Sa(ety
Wor!sheet # High *oltage System
Wor!sheet +# H* )attery State o( Charge
%$D +# Highlander Hybrid ,'S on 'ico Sco-e
Wor!sheet .# Techstream /Hybrid ,'S %nitialiation
,lectric Air Conditioning System
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Hybrid SystemO"er"iew
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Toyota Hybrid Technology
Toyota has beenresearching emissionred#ction technologysince %&'()
Toyota is theworld leader inhybrid technology)
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Toyota Hybrid System /THS
Hybrid Transa&le
5otor 6 enerator 15otor 6 enerator 2
%n"erter
189:; =0 'rius
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H* Transa&le
: 5otor enerator 1 /51
: 5otor enerator 2 /52
%n"erter
Assembly H* )attery
@ear Dri"e nit: 5otor enerator @ear /5@
/+WD:i Only
,ngine
Hybrid System O"er"iew /THS %%
Highlander Hybrid
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=01 > =0 'rius189:; =0B 'rius4189:;
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Hybrid Transa&le
* "$%
* "$+
@ear Dri"e nit
* "$, -shown.
Hybrid Transa&le
* "$%
* "$+
@ear Dri"e nit
* "$, -shown.
H* Transa&le
: 5otor enerator 1 /51
: 5otor enerator 2 /52
@ear Dri"e nit
: 5otor enerator @ear /5@
/+WD:i Only
Hybrid Dri"etrain Com-onents
Highlander Hybrid
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%n"erter
!ontrols c#rrent to
motor generators lso provides correct
voltages to other
systems)
%n"erterAssembly
Hybrid Dri"etrain Com-onents
Highlander Hybrid
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H* )attery
H* )attery
Stores electrical
energy to drive
the system
Hybrid Dri"etrain Com-onents
Highlander Hybrid
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Hybrid *ehicle Sa(ety 'recaution
2010 'rius
All hybrid system high:"oltage wire harnesses are orange4
The H* battery and other high:"oltage com-onents ha"e
High *oltage caution labels4
Do not carelessly touch these wires and com-onents4
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Hybrid System Control 5odes
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1.071 Toyota Hybrid System
@,AD
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,ngine Starting
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$ight Acceleration
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$ight $oad Cruise
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;ull Acceleration
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Deceleration
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@e"erse
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,nergy 5onitor E ;uel Consum-tion Dis-lay
Highlander Hybrid
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%nsert the !ey /non:
Smart Fey eGui--ed
0+ > =0B 'rius only
!!
O//
0$*O1
,E23
'ush the 'OW,@
switch with the bra!e
-edal de-ressed
*ehicles enters
@,AD mode
'ush )utton Start
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Wor!sheet 1
Wal!around
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Wor!sheet 2
Test Dri"e
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Warning $ights
=0+ > =0B 'rius
@,AD $ight
5aster Warning $ight
5al(unction %ndicator $ight
$ow
tem-erature
indicatorlight
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I,8D 5odule 1 O"er"iewJ
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Transa&le
O-eration
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0071 Toyota Hybrid System
Hybrid Transa&le
=01 > =0 'rius
51
52
'lanetary ear nit
Silent Chain
Transa&le Dam-er
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Construction o( 51
=01 > =0 'rius@otorStator Coil
@esol"er
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Construction o( 52
=01 > =0 'rius
Stator Coil @otor
@esol"er
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071 Toyota Hybrid System
5otor6enerators
2010 'rius Total weight is red#ced approximately 445
"$+ maxim#m o#tp#t is increased to 67 HP
51
52
Previo#s "odel +7%7 Pri#s P,08S
5ore com-act9 more light
weight design achieved
thro#gh centrali:ed winding o;the coils)
5otor rotational s-eed was
signi(icantly increased9
improving power per;ormance
P%%+ P
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Construction o( 5@
Highlander Hybrid
Stator @otor@esol"er
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S-eed Sensor /@esol"er O-eration
2etects magnetic pole position
HV E!8 #ses the ,esolver as a
speed sensor and calc#lates
position variations
!oil
!oil B
!oil !
"agneti:edSide
O#tp#t
Side@otor
Stator
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'ermanent 5agnet 5otor enerator
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'+10 Hybrid Transa&le
2010 'rius
52
Com-ound ear nit
'ower S-lit 'lanetary
ear /@ight Side
5otor S-eed @eduction
'lanetary ear
/$e(t Side
Oil 'um-
/5echanical
51
;inal Dri"en ear
Counter Dri"en ear
Di((erential ear nit
Transa&le Dam-er
;inal Dri"e ear
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Com-ound ear nit : Com-onents
2010 'rius
Com-ound ear nit
'ower S-lit'lanetary ear nit
Counter Dri"e ear
/Com-ound ear
5otor S-eed
@eduction 'lanetary
ear nit
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Com-ound ear nit : O-eration
Highlander Hybrid
52 51
,ngine
Carrier
Counter
Dri"en ear
/To Wheels
Carrier
@ing ear
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Transa&le Dam-er
2010 'rius
coil = tor>#e limiter provide damping
Transa&le Dam-er
Coil s-ring
TorGue limiter
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'112 Hybrid Transa&le Ser"ice
=0+ > =0B 'rius
Ado-ts a shi(t
control actuator Oil -an is
discontinued E WSty-e AT; is used
Drain 'lug
/(or AT;
;iller 'lug
/(or AT;
Drain 'lug
/(or Coolant
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'+10 Hybrid Transa&le Ser"ice
2010 'rius
;luid Ty-e WS
Ca-acity 4. Gts
5aintenance %nter"al/initial
100000 miles
5aintenance %nter"al/subseGuent
.0000 miles
Drain 'lug (or Hybrid
Transa&le ;luid
;iller 'lug (or HybridTransa&le ;luid
Drain 'lug (or Hybrid
System Coolant
'11 H b id T l S i
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'11 Hybrid Transa&le Ser"ice
Camry Hybrid
WS ;luid Drain 'lug
/10mm he&
WS ;luid ;ill 'lug
/10mm he&
Hybrid System Coolant
Drain 'lug
/10mm he&
0 to 0420
in4
Shi(t C t l '111
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Shi(t Control > '111
=01 > =0 'riusShi(t 'osition Sensor
H*
,C ,ngine,C
/,C5
Combination
5eter
),A8
Shi(t A bl '112
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Shi(t Assembly > '112
=0+ > =0B 'rius
Select Sensor
Shi(t Sensor
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' !i $ ! 5 h i '112
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'ar!ing $oc! 5echanism > '112
=0+ > =0B 'rius
@eGuest
Hybrid Transa&le
'ar!ing $oc!
5echanism
Shi(t ControlActuator
T65
Control
,C
H* ,C
Control
'ositionK'L or K8ot 'L
'ar!ing Switch
Shi(t $e"er
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D i 5 d
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+B071 Toyota Hybrid System
Dri"e 5odes
2010 'rius,CO 5OD,
5oderates the res-onse to accelerator -edal
o-eration to o-timie (uel economy 5oderates the A6C -er(ormance to o-timie
(uel economy
,* 5ode Dri"ing with only the electric motor
'W@ 5OD,
O-timies acceleration -er(ormanceby increasing the moti"e (orce in
relation to accelerator -edal o-eration
Accelerator 'edal O-ening Angle
'W@
5ode
8ormal
,CO
5ode
5oti"e;orce
Out-ut
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Ser"ice Ti- '11
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Ser"ice Ti- : '11
Camry Hybrid
Transaxle !ontrol !able d?#stment
Slider
Shi(t Cable
+
.
$oc! 'iece
1
2
Shi(t to 8 range
%nstructor $ed Demo
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%nstructor $ed Demo
Transa&le Assembly E
'arts %denti(ication
I,8D 5odule 2 Transa&le O-erationJ
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I,8D 5odule 2 Transa&le O-erationJ
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Certi(ied Hybrid *ehicle Technician
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Certi(ied Hybrid *ehicle Technician
!8T0O1!8T0O1
This mod#le does not certi;y yo# to work on hybrid vehicle high*voltage systems)
The !erti;ied Technician mustcomplete co#rse 7'% @ Toyota Hybrid System to
sa;ely begin working on Toyota hybrid vehicles)
8ntil yo# complete co#rse 7'%A1ever to#ch9 disassemble9 remove or replace the high*voltage parts9 cables and
their connectors) -High*voltage parts and cables are colored orange or have high*
voltage warning labels).
2o not try to access the service pl#g)
/ail#re to comply with these warning can ca#se severe b#rns or electric shock that
may res#lt in death or serio#s in?#ry)
Hybrid *ehicle Sa(ety
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Hybrid *ehicle Sa(ety
'ower Cable @outing 'rius
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,ngine @oom
Munction )loc!
'ower Cable @outing > 'rius
=01 > =10 'rius%n"erter H* )attery
Au&iliary
)attery
A6C Com-ressor
Au&iliary
)attery
%n"erterH* )attery
2001:200 'rius 200+:200B 'rius
2010:u- 'rius
H* )attery
%n"erter
A6C Com-ressor Munction )loc!
,ngine @oom
Munction )loc!
'ower Cable @outing Other 5odels
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'ower Cable @outing > Other 5odels
Highlander Hybrid
)attery Smart nit EH* @elay Assembly
A6C Com-ressor
%n"erter
Assembly H* )attery
DC:DC Con"erter
Camry Hybrid
A6C Com-ressor
'ower Steering Con"erter
H* @elay Assembly
@ear Dri"e
nit /5@
%n"erterAssembly H* )attery
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H* )attery
8ic!el:5etal Hydride )attery
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8ic!el:5etal Hydride )attery
=0+ > =0B 'rius
The 1ickel*"etal Hydride
-1i*"H. hybrid vehicle -HV.battery stores electrical
energy to drive the system)
1ominal battery voltagesA
=7%*=74 Pri#s =7< = later Pri#s Highlander Hybrid !amry Hybrid
27+ *DC 202 *DC 2?? *DC 2+. *DC
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H* )attery : $ayout
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H* )attery : $ayout
=0+ > =0B 'rius
S5@
S5@ 2
S5@ 1
)attery ,C
H* )attery
5odule
@ear )us )ar
5odule
;ront )us )ar
5odule
H* )attery : Com-onents
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H* )attery : Com-onents
2010 'rius
CAT%O8#The H* battery is a high:"oltage com-onent that only Certi(ied Hybrid Technicians
should ser"ice4
H* )attery
/)attery 5odules )attery Smart
nit
Tem-erature Sensors
/(or battery modules
H* Munction
)loc! Assembly
H* )attery
Cooling )lower
H* )atteryTem-erature Sensor
/(or inta!e air
H* )attery State o( Charge /SOC
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H* )attery State o( Charge /SOC
,&am-le o( change in SOC
ndercharged region
O"ercharged region
Controlregion
Time
SOC
Target SOC control
--er SOCcontrol limit
$ower SOC
control limit
System 5ain @elays /S5@
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System 5ain @elays /S5@
2010 'rius
8ote# Do 8OT remo"e S5@s on the H* Nunction bloc! assembly4
Ser"ice'lug
S5@)
S5@'
S5@
@esistor
)attery5odules
H* )attery
Current Senor
'ower 5anagement
Control ,C /H* C'
H* )attery
Current Sensor
'recharge
@esistor
S5@)
S5@'
S5@)attery
Smart nit
S5@ Control
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S5@ Control
S5@2
S5@1
S5@
Ser"ice 'lug
/ to %n"erter
/: to %n"erter
8D to THS ,C
High:
*oltage
;use
@esistor
'rius > H* )attery Cooling
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'rius H* )attery Cooling
2010:u-
'rius200+:200B
'rius
2001:200
'rius
H* )attery Cooling
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H* )attery Cooling
2007:2010Camry Hybrid
2003:2007
Highlander Hybrid
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%n"erter
%n"erter Assembly
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%n"erter Assembly
Highlander Hybrid
)oost Con"erter288 VDC - 650 VDC
%n"erterAC - DC
DC:DC Con"erter288 VDC - 12 VDC
5 ,CControls inverter
components
HSD %n"erter
Toyota Hybrid System Charger
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Toyota Hybrid System Charger
;ront
)ac!
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Sa(ety Ste-s
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're-aration
Ser"ice Ti- : H* )attery
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- y
Preca#tions be;ore working on hybrid system
@ 0; 2T! P7 orP477& are set9 tro#bleshoot the 2T! %st)
2T! 2etailed 0n;ormation
!ode 2isplay 01/ !ode 0n;ormation -Tro#ble rea.
P7 Hybrid BatteryVoltageSystem
0solation /a#lt
(+ 0ns#lation abnormality o; the entirehigh*voltage circ#it
%% Electric !ompressor = C! 0nverter
%+ HV Battery9 Battery Smart 8nit9 HV,elay ssembly
%4 Hybrid Transmission9 0nverter with!onverter ssembly
%< 2! High*voltage rea
@,AD O;; E Securing Smart Fey
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g y
A--ro&4 10 (t4 radius
/not to scale
Service Sho#ld be per;ormed with ,E23 O// = key removed
;rom ignition)
Sec#re the smart key at least %7 ;eet away ;rom the vehicle to
provide additional sa;ety)
2isconnect the cable ;rom a#xiliary battery negative terminal)
'ersonal 'rotecti"e ,Gui-ment /'',
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G - /
,lectrical insulating
glo"es must be wornwhen wor!ing with
Hybrid com-onents4
Class =0 glo"es o((er
adeGuate -rotection (or
Toyota Hybrid "ehicles4
Class 5a&4 se *oltage AC Class 5a&4 se *oltage AC
=$ow *oltage =High *oltage
00 .00 1 7.00
0 1000 2 17000
23.00
+ 3000
5a&imum se *oltage AC
'', : lo"e 'rotectors and $iners
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Protector gloves may be omitted ;or
!lass 7 $loves9 #nder limited #seconditions9 where small e>#ipment and
parts manip#lation re>#ire #n#s#ally
good ;inger dexterity)
!lean9 dry cloth gloves may be worn
inside o; ins#lating gloves ;or warmth in
cold weather or to absorb perspiration
in hot weather)
'', > Certi(ication E @e-lacement
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-
$loves that have been in*service ;or six months m#st eitherA
%)Be sent o#t ;or electrical testing or
+)2isposed o; and replaced with new $loves)
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-ur-ose is to create an e&tra -age (or handboo! te&t4
%nsulated lo"e 'rocedures
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%5'O@TA8TA 2O 1OT 8SE $DOVES 0/
THE3 ,E FET O, 2"P)
0T 0S /TE, THE T,ST%8 28E 2TE ",GE2 O1 THE
!8//S -O, "O,E TH1 "O1THS /,O" 2TE O/ %SS,.)
Steps to be taken by the wearer9 ,*,@ T%5, ),;O@, p#tting
the $loves onA
,emove all rings and bracelets to avoid any damage to the
$loves)
Fash hands with a mild soap = dry hands thoroughly be;orep#tting on the $loves)
%nsulated lo"e Care E Storage
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8ote#Expos#re to chemicals9 solvents9 o:one9 aging = extremetemperat#res can degrade gloves)
/ollow the instr#ctions ;or the care9 decontamination =
maintenance provided by the glove man#;act#rer or s#pplier)
$ood ho#sekeeping can help extend glove li;e)
lso9 keep yo#r work area clean ;rom contaminants)
$loves m#st be stored in their nat#ral shape = protected ;rom
physical damage)
$loves sho#ld be stored in cool9 dark = dry location)
$loves may be kept inside o; a bag9 box9 or container
designed ;or = #sed excl#sively ;or them)
%nsulated lo"e %ns-ection
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Be;ore #se9 check the ins#lated gloves ;or cracks9 tears and othertypes o; damage by per;orming the ;ollowing proced#re)
%) Place the glove on its side
+) ,oll the opening #p + or 4 times
4) /old the opening in hal; to close it
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-ur-ose is to create an e&tra -age (or handboo! te&t4
Caution 8oti(ication E 5anaging Sa(ety
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8se the provided sign statingA
CAT%O8# H%H *O$TA,4
DO 8OT TOCH D@%8 O',@AT%O8
Best Practices incl#deA!on;irming that the work area is dry)
!on;irming that the areas aro#nd the hybrid components
-HV battery9 inverter. are dry)
!reating and maintaining a sa;e :one aro#nd hybrid vehicle
as appropriate)
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Ser"ice 'lug >
@emo"al
Ser"ice 'lugs
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'rotecti"e Co"er@ear Door Scu(( 'late $H
4 Steps to remove Darge type Service Pl#g
+ Steps to remove Small type Service Pl#g
1
2
2
1
http://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/service%20plug%20removal.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Prius%20service%20plug.exe7/25/2019 Toyota Hybrid Presentation
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Hybrid *ehicle %n"erter 'recautions
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Time discharges the capacitors)
Time
High:"oltage Condensers
2is
cha
rge
Electricity0*
Ser"ice -lug remo"al 5OD,$ Discharge
WA%T T%5, (rom Ser"ice
'lug @emo"al
2001:200B 'rius . minutes
2010:u- 'rius 10 minutes
Highlander Hybrid . minutes
Camry Hybrid 10 minutes
%nstructor $ed Demo
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%n"erter Assembly E
'arts %denti(ication
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During H* @e-air
Hybrid Ser"ice Sa(ety 'recautions
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Prevent cond#ctive ob?ects ;rom completing the circ#it betweenenergi:ed cond#ctors)
2o not #se a #niversal ?oint) 0t can rotate accidentally =
complete a circ#it)
Deaving the battery case open witho#t the cover may expose
others to high voltage ha:ard) 8e"er leave the HV battery#nattended with the cover o;;)
)est 'ractices
%nsulating Connectors
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CAT%O8A
2o not to#ch any bare cables that may have high*voltage) !over disconnected high*voltage connectors with ins#lating
vinyl tape
%nsulated *inyl Ta-e
Chemical Haards
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Highlander Hybrid
Dont touch!Dont touch!
0; electrolyte is present at the bottom o; the battery case9
a"oid contact with the (luid)
H* )attery @ecycling O"er"iew
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ll hybrid vehicle HV batteries are recyclable see Farranty Parts
,ecovery Program ;or details)
'roceed with @e-air
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8ew 8ut Old 8ut
Some inverter n#ts and
bolts cannot be re#sed)
See ," ;or inverter
installation details)
H* )attery 'ost Cleaning
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On some early models the battery
-osts may show signs o( corrosion4This issue was addressed by S-ecial
Ser"ice Cam-aign +04
%nstructor $ed Demo
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=0+ > 0B 'rius H*
)attery =10 'rius H*
)attery Camry H*)attery Highlander H*
)attery Assembly E 'arts
%denti(ication
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A(ter H* @e-air
Hybrid *ehicle @e-air > Puality Chec!s
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A(ter
@e-air
STA@T
'otential
Damage
%nstallation
Hydrogen*ent Hose
Ser"ice 'lug %nstallation A(ter @e-air
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Small Ser"ice 'lug %nstallation# $arge Ser"ice 'lug %nstallation#
2
1
Clic! is
heard
1
2
'recautions (or DC:DC Con"erter
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2010 'rius
Wor!sheet E +
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H* Systems State o( Charge /SOC
I,8D 5odule High *oltage SystemJ
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,ngine=10 E later 'rius# 29@:; =0B 'rius# 189:;
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107071 Toyota Hybrid System
=0+ > =0B 'rius
Highlander HybridV EngineA +76 HP
/ront 2rive "otorA %( HP
,ear 2rive "otorA ' HP
HV BatteryA I 7 HP
Actual HP 268 HP
Pri#s $en +%)(D EngineA ' HP
/ront 2rive "otorA 6 HP
HV BatteryA I 4< HP
Actual HP 110 HP
!amry Hybrid
EngineA %
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2010 E $ater 'rius
29@:;
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10B071 Toyota Hybrid System
=0+ > =10 'rius
=0+:0B 5 =10 E later
,ngine 189:;
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110071 Toyota Hybrid System
2010 'rius
,ngine Coolant
Cross Section
,@ as
,@ Cooler
;rom ,@ Cooler
To %nta!e
5ani(old
*al"e
Coil,@ *al"e
Silicon Chi-
5A' Sensor
/*acuum Sensor
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This slide is hidden4 %t does not a--ear in the slide show4 %ts
-ur-ose is to create an e&tra -age (or handboo! te&t4
,lectric Water 'um-
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2010 'rius
,lectric Water 'um-
Sha(t
5otor
Stator
@otor
,lectric Water 'um-
1o accessory belt 1ew ctive Test and
2ata Dist items 1ew 2T!s ;or p#mp
Cooling System Com-onents
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2010 'rius
@eser"oir Tan!
,lectric Water
'um-
Throttle )ody
;rom @adiator
To @adiator
To ,&haust 'i-e as
Control Actuator
;rom ,&haust 'i-e as
Control Actuator
,@ *al"e
,@ Cooler
Coolant Tem-erature Sensor
Air @elease *al"e
;rom Heater Core
To Heater Core
,&haust Heat @ecirculation System
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2010 'riusCoolant Tem-erature Switch
,&haust 'i-e asControl Actuator *al"e
,ngine ,ngine
Coolant
,&haust as
*al"e is closed/Coolant Cold
*al"e is o-en/Coolant Warmed -
@od
Combination 5eter
,&haust Heat @ecirculation 'arts
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2010 'rius
,&haust 'i-e as
Control Actuator
,&haust 'i-e as
Control Actuator Case
,&haust 'i-e as
Control Sto--er
as!et
,ngine Coolant Change
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113071 Toyota Hybrid System
2010 'riusAir @elease *al"e
Service Tip * ;ollow
,epair "an#alproced#res care;#lly =
#se the air release
valve to remove all air
;rom the system)
@adiator Drain
Coc! 'lug
Air @elease
*al"e
@eser"oir
Tan! Ca-
Cylinder )loc!
Drain Coc! 'lug
Coolant Ty-e S$$C
Ca-acity 747 Gts
5aintenance %nter"al/initial
100000 miles
5aintenance %nter"al/subseGuent
.0000 miles
Ser"ice Ti-s /,ngine Coolant Change
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117071 Toyota Hybrid System
8se the air release valve to remove air ;rom
the system)
dd SDD! to B line o; reservoir tank)
S>#ee:e inlet = o#tlet hoses = then check
coolant level)
,#n engine in inspection mode to warm it #p) ;ter the
thermostat is open9 allow coolant to circ#late ;or
several min#tes -approximately ' min#tes.)
) $ine
;$$
$OW ;ter the engine has cooled9 check that
coolant level is between /8DD = DOF
2010 'rius
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=0+ > =0B 'rius
189:;
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11B071 Toyota Hybrid System
=0+ > =0B 'rius
Water 'um-
/(or coolant heat
storage system
to heter core
,ngine Coolant Tem-4 Sensor
/(or coolant heat storage system
,ngine Coolant Tem-4 Sensor
/(or engine control system
Coolant ;lowControl *al"e
Water 'um-
/(or heater
Coolant Heat
Storage Tan!
@e"erse *iew
Coolant Heat Storage Tan!
=0+ =0B ' i
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120071 Toyota Hybrid System
=0+ > =0B 'rius
)leeding air(rom the
system is
critical
Drain 'lug
Outlet Tem-4 Sensor
to"rom
#ter Vlve
'um-
'rius Coolant Heat Storage O-eration
=0+ =0B ' i
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4)( V -VDV
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122071 Toyota Hybrid System
=0+ > =0B 'rius
S-eci(ications
/l#id Toyota S#per Dong Di;e!oolant -SDD!.
!apacity &)% >t -6) D.
Ser"ice Ti-A ,e;er to the ,epair "an#al ;or details)
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12071 Toyota Hybrid System
=01 > =0 'rius
189:;
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12+071 Toyota Hybrid System
=01 > =0B 'rius
%nta!e 'i-es
Throttle Control
5otor
Throttle 'osition
Sensor
Surge Tan!
=01 =0 'rius
HC Adsorber and Catalyst /HCAC
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01 > 0 'rius
V0EF H! 2SO,PT0O1 !TD3ST S3STE"
ActuatorHC Adsorber
)y-ass *al"e ClosedTWC
TWC
5ain 5u((ler
TWC with
HC Adsorber
THS ,ngine Coolant Change
http://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_HCAdsorption.exe7/25/2019 Toyota Hybrid Presentation
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S-eci(ications
/l#id Toyota S#per Dong Di;e!oolant -SDD!.
!apacity ()+ >t -
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127071 Toyota Hybrid System
Highlander Hybrid 59:;,
Camry Hybrid 2A9:; ,ngine Coolant Change
2003 : 2007 Highlander Hybrid 200? : 2010 Highlander Hybrid
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12?071 Toyota Hybrid System
S-eci(ications
/l#id Toyota S#per Dong Di;e !oolant -SDD!.
!apacity %4)( >t) with rear heater%%)+ >t) witho#t rear heater
Ser"ice Ti-A ,e;er to the ,epair "an#al ;or details
2003 : 2007 Highlander Hybrid 200? : 2010 Highlander Hybrid
@adiator Drain Coc! 'lug
@adiator Drain Coc! 'lug
/,Gui--ed with *ent 'lug
Cylinder )loc! Drain Coc! 'lug
@adiator Ca-
@adiator Drain Coc! 'lug
@adiator Drain Coc! 'lug
/,Gui--ed with *ent 'lug
Cylinder )loc!
Drain Coc! 'lug
@adiator Ca-
Camry Hybrid > ,ngine Coolant Change
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12B071 Toyota Hybrid System
@adiator Ca-
Cylinder )loc! DrainCoc! 'lug
@adiator DrainCoc! 'lug
S-eci(ications/l#id Toyota S#per Dong Di;e !oolant -SDD!.
!apacity ) >t)
Ser"ice Ti-A ,e;er to the ,epair "an#al ;or details)
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,*A'
=01 > =0B 'rius# 189:; =0 'rius
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11071 Toyota Hybrid System
01 0 'rius
@esin )ladder
;uel Sender
5ounting
Steel Tan!
%nterior
Sub Tan!
;uel Sender auge
=01 > =0 'rius
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12071 Toyota Hybrid System
01 0 'rius
BodyE!8
"eter
E!8 2isplay
Combination 5eter
;uel Sender
auge
;loat
@eed
Switch
%nclination Sensors
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1071 Toyota Hybrid System
=01 > =0 'rius
Sender
auge
Signal
Combination 5eter
%nclinationSensors
5ain Tan!
AmbientTem-4Sensor
5eter
,C
;uel
Senderauge
)ody
,C
Combination 5eter
%nclinationSensors
5ain Tan!
AmbientTem-
Sensor
5eter
,C
;uelSenderauge
=0+ > =0B 'rius
,*A' Control Com-onents
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=01 > =0 'rius
;resh Air
$ine
*S* /(or CanisterClosed *al"e
=0+ > =0B 'rius
,*A' Control Com-onents
=0+ > =0B 'rius
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1.071 Toyota Hybrid System
Air CleanerThrottle *al"e
@e(uel Chec!
*al"e
;iller 'i-e
Charcoal
Canister
*S* /(or Canister
Closed *al"e
*a-or 'ressure
Sensor
;uel Tan!
Tra- ;ilter
*S* /(or ,*A'
,*A' $ine
,C5
*S* /(or 'urge ;low
Switching *al"e
;resh Air
$ine
O@*@ @,;,$%8
'@%8
http://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_EVAP_Purge.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_EVAP_Refuel.exe7/25/2019 Toyota Hybrid Presentation
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,*A'
Highlander Hybrid#59:;,
Closed ;uel Tan! System
Highlander Hybrid
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17071 Toyota Hybrid System
g y
THS
,C
Canister
;uel Outlet *al"e/Closed
;uel *a-or
Containment *al"e
'um- 5odule
@e(ueling 'rocedure
Highlander Hybrid
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g y
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1B071 Toyota Hybrid System
,*A'
=10 E $ater 'rius#29@:;
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1+0071 Toyota Hybrid System
Fey O(( ,*A' System
)ladderless layered
-lastic (uel tan!
;uel 'um- Assembly* ;uel ;ilter* 'ressure @egulator* ;uel Sender auge
12:hole Ty-e
;uel %nNector
Puic! Connector
;uel Deli"ery
'i-e
;uel System > Fey O;; ,*A'
2010 'rius
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;uel Cut:o(( *al"e
,C5
'urge
*S*
Canister 'ressure Sensor
Air %nlet
$ine
$ea! Detection 'um-
;uel ;iller Chec! *al"e
;uel Tan!
Vent $ine
I'um- 5oduleJ
Charcoal
Canister
*ent
*al"eAir ;ilter
%ur&e $ine
R The -urge *S* control has changed and the -urge (low "olume
increased4
Diagnostic %ns-ection 5odes
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Change to % O;; > ins-ection mode is canceled
O;;
%:O8
/but not
@,AD O8
De-ress
2 times
Accelerator
'edal
De-ress
2 times
De-ress
2 times
within 30 seconds
/F2 0nspection "ode
%:O8
@,AD
O8
I,8D 5odule + ,ngineJ
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1+071 Toyota Hybrid System
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1++071 Toyota Hybrid System
)ra!e System
,lectronically Controlled )ra!es /,C)
5ain )ody ,C'ower 5anagement Control ,C
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1+.071 Toyota Hybrid System
)ra!e )ooster with 5aster Cylinder
'um- Assembly
w6 Accumulator
)ra!e 5aster Cylinder
@eser"oir
Wheel S-eed Sensor
)ra!e 'edal
Stro!e Sensor
5ain )ody ,C
Steering Angle
Sensor
aw @ate and
Acceleration Sensor
'rius ,C) $ayout
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1+3071 Toyota Hybrid System
2001>200#Hydraulic )oosted
5aster Cylinder
200+ to 200B#,lectronic )ra!e Actuator
with Stro!e Simulator2010:u-#
Hydraulic )ra!e )oosterwith Stro!e Simulator
)ra!e System Com-arison
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=01 > =0 'rius =0+ > =0B 'rius =10 E later 'rius HighlanderHybrid
Camry Hybrid
@egenerati"e )ra!e Coo-erati"e Control
A)S w6 ,)D
Hydraulic)ra!e
)oosterR
,lectronically Controlled )ra!ing /,C)
: )ra!e Assist
: RR T@AC
: : HAC :
: ,nhanced *SC *SC
: : : *D%5
M Three channel E!B
MM "otor Traction !ontrol ;#nction o; HV E!8 provides a similar ;#nction
)ra!e Control System : A--ortioning o( ;orce
2010 'rius
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1+?071 Toyota Hybrid System
Hydra#lic = regenerative ;orce
@egenerati"e
)ra!ing ;orce
Hydraulic
)ra!ing ;orce)ra!ing
;orce
Time
Dri"ers Demand
Changes in )ra!ing ;orce A--ortionment
,lectronically Controlled )ra!ing System
Highlander Hybrid)ra!e 'edal Stro!e Sensor # ,lectrical Signal
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Hydraulic )ra!e ;orce
)ra!e ;orce
@egenerati"e
)ra!e ;orce
S!id Control ,C
5aster Cylinder
'ressure Sensor
Hydraulic 'ower
Source 'ortion
Hydraulic Control
'ortion
THS:%%
,'S
# ;luid 'ressure
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1.1071 Toyota Hybrid System
Accumulator6
Actuator
5aster Cylinder
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1.2071 Toyota Hybrid System
)ra!e )ooster with 5aster
Cylinder
)ra!e Actuator
Stro!e
Simulator
)ra!e Actuator
Skid !ontrol E!8
+ Dinear Solenoid Valves
< Switching Solenoid Valves
6 !ontrol Solenoid Valves Press#re sensors ;orA
* ,eg#lator
* Fheel !ylinder
* cc#m#lator
)ra!e Hydraulic Circuit
2010 'riusAccumulator
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1.071 Toyota Hybrid System
'um- 5otor
Hydraulic )ra!e )ooster
# @egulator 'ressure Sensor
# Accumulator
'ressure Sensor
# Wheel 'ressure Sensor
# $inear Solenoid *al"e
# Switching Solenoid *al"e
# 'ressure @eduction
Solenoid *al"e
# 'ressure Holding
Solenoid *al"e
Stro!eSimulator
;@ @H;@ $H @@ $H @@ @H
)ra!e Actuator
;luid $e"el
Warning
Switch
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1.+071 Toyota Hybrid System
Warning $ights
)ra!e Control System : Combination 5eter
2010 'rius
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1..071 Toyota Hybrid System
Farning light ill#mination
BrakeFarning
Dight C 3ellow
BrakeFarning
Dight C ,ed
BS FarningDight
VS! Slip0ndicator
T,! -T,!.9 VS! or H! operation * * * 0ll#minate
"al;#nction in BS9 EB2 or B * * 0ll#minate *
"al;#nction in T,! -T,!. or VS! * * Blink
"al;#nction in the apportioning o; brake * 0ll#minate * *
Parking brake O1 or low brake ;l#id level * 0ll#minate * *
System mal;#nction not a;;ecting brake ;orce 0ll#minate * *
Warning $ight
Conditions
Shown above is the +7%7 Pri#s) Other "odels are similar)
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1.3071 Toyota Hybrid System
Ser"ice Details
,C) tilities
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1.7071 Toyota Hybrid System
Ser"ice Ti- : )ra!e ;luid $e"el
2010 'rius
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1.?071 Toyota Hybrid System
d?#st the ;l#id level in the reservoir between "01 line
= /l#id Devel S#pport Dine)
5A< $ine
;luid $e"elSu--ort $ine
5%8 $ine
)ac!u- Control 'ower Source
Highlander Hybrid
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Ca-acitor Cell
I,8D 5odule . )ra!esJ
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131071 Toyota Hybrid System
,lectric 'ower
Steering
,lectric 'ower Steering /,'S
Provides power assist even
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132071 Toyota Hybrid System
Provides power assist even
when engine is not r#nning)
0mproves ;#el economy)
!ons#mes energy only
when assist is re>#ired)
,lectric 'ower Steering Com-onents
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13071 Toyota Hybrid System
200+ and later 'rius
200? and later Highlander Hybrid
,'S,'S
,C,C
TorGue sensorTorGue sensorDC motorDC motor
,'S,'S
,C,C
TorGue sensorTorGue sensor
DC motorDC motor
2001>200 'rius Camry Hybrid and
2003>2007 Highlander Hybrid
DC motor
TorGue sensor
,'S : TorGue Sensor
TorGue Sensor DC 5otor
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=01 > =0 'rius
Torsion
)ar
Detection@ing 1Detection
@ing 2
Detection@ing
Detection Coil Correction
Coil
=0+ > =0B 'rius
TorGue Sensor *ideo TorGue Sensor Animation
,'S Steering System Diagram
=0+ > =0B 'rius
http://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_Torque_Video.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_Torque_Video.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_Torque_Sensor.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_Torque_Video.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_Torque_Video.exehttp://e/2010%20Advanced%20Automotive%20Hybrid%20Technology%20Institute/TOYOTA/071_Toyota_Hybrid_Systems_Presentation_10-01-09/Animations/Toyota_Torque_Video.exe7/25/2019 Toyota Hybrid Presentation
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TorGue Sensor
DC 5otor
,'S ,C
ateway ,C
S!id Control ,C 5eter ,C
H* ,C
5ulti Dis-lay*ehicle S-eed
signal
Assist torGue
demand signal /(or
,nhanced *SCR
5aster Warning
$ight
,'S Warning
Dis-lay @eGuest
Signal to 5ulti
Dis-lay
Warning dis-lay
@,AD signal
D$C
Steering System Diagram
2010 'rius
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133071 Toyota Hybrid System
'ower
Steering ,C
SteeringAngle
Sensor
* )us 8o41
)oost
Con"erterR
Combination5eter
TorGue Sensor
@otation Angle SensorR
'ower Steering 5otor
Steering Column Assembly
R5odels with
brushless ty-e motor
'ower5anagement
Control ,C
S!id Control,C
*ehicle
S-eed Signal
D$C
)rushless E )rush Ty-e ,'S
2010 'rius
'ow
er
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137071 Toyota Hybrid System
'ower
Steering ,C
Steering Column Assembly* )rush:ty-e 'ower Steering
5otor* TorGue Sensor
Steering Column Assembly* )rushless:ty-e 'ower
Steering 5otor* TorGue Sensor
* @otation Angle Sensor
Ser"ice Ti-# The rotation angle sensora#tomatically initiali:es when the vehicle is
driven at ++I mph ;or ( seconds with a low
yaw rate -straight ahead driving.)
'ower
Steering ,C
Steering : Di((erence (rom 're"ious 5odel
=0+ > =10 'rius
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%tem 2010 E $ater 'rius =0+ > =0B 'rius
ssist Docation Type !ol#mn
Power Steering E!8 2etails 1)) FCTemperat#re Sensor %
Voltage Boost !ontrolM9 + 1))
"otor 2etails 2! "otor
Br#sh type -%(*inch wheels.
or Br#shless 4*phase "otorM9 +Br#sh type
,otation ngle Sensor ,esolver TypeM 1))
Tor>#e Sensor Hall 0! Type 0nd#ctance Type
,ed#ction "echanism Form = Fheel $ear
MA "odels with br#shless type power steering motor only -%'inch wheels.
Ser"ice Ti- > ,'S %nitialiation
2010 'rius
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Per;orm initiali:ation = calibration on +7%7 Pri#s EPS as ;ollowsA
@e-air 5otor Ty-e @otation AngleSensor
%nitialiation
TorGueSensor 9ero
'ointCalibration
Assist 5a-Writing
E!8 replacement !ol#mn assy)
replacement
De;t or right e;;ortdi;;ers
Br#sh
O O
Br#shless O O O
Ser"ice Ti- > S-iral Cable
2010 'rius
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Spiral !able wCSteering ngle Sensor is a complete assembly
Do not remo"e the steering angle sensor (rom the
s-iral cable Do notre-lace or rotate the s-iral cable with the
battery connected E engine switch O8
Combination
Switch Assembly
S-iral Cable
Steering Angle
Sensor
S-iral Cable with
Steering Angle Sensor
Ti-A Ens#re that the steering wheel is installed = aligned
straight when inspecting the steering sensor)
,'S Com-onents
Highlander Hybrid
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THS ,C
,'S ,C
Steering ear nit
S!id Control ,C
DC : DC Con"erter /(or ,'S
Combination 5eter
'6S Warning $ight
,'S Steering System
Highlander Hybrid
CA8
ateway ,C
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),A8 -0nstr#ment Panel B#s.
*oltage# 2?? "olts
,'S ,C
Tem-erature
Sensor
*oltage# +2 "olts
TorGue Sensor
@otation Angle Sensor
5otor
DC:DC Con"erter/(or ,'S
D$C
THS ,C
N@,AD signal
S!id Control ,CN*ehicle S-eed
signalNAssist torGue
demand signal
5eter ,C
N'6S Warning
$ight
H* )attery
2003:2007 Highlander Hybrid : 'ower Steering 'recaution
=03 > =07 Highlander Hybrid
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The yellow power steering
wire harnesses carry
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Highlander ,'S
I,8D 5odule 3 ,'SJ
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Air Conditioning
Air Conditioning Com-ressor
=01 > =0 'rius
S l ti "K C!
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Selecting "K C! on
the 7%*74 Pri#s willca#se the engine to r#n
contin#o#sly)
'TC Heater
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'TCHeaters
%nsulation;ilm
'TC,lement
,lectrode
=01 > =0 'rius
'TC
,lement)rass
'late
Aluminum
;in
=07 E later Camry Hybrid
,lectric Coolant 'um-
Provides stable heater per;ormance even with engine stopped
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p g pp
)y-ass *al"e Close ;rom,ngine ToHeater
01 > 0 'rius Highlander Hybrid
0+ > =0B 'rius
;rom
,ngine
To
Heater
5ain Air Conditioning Com-onents
=0+ > =0B 'rius
Solar Sensor
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,lectricCom-ressor
A6C %n"erter
A6C Water 'um-
Solar Sensor
@oom Tem-4 EHumidity Sensor
A6C ,C
Heater Core 'TC Heater
,"a-4Tem-4Sensor
)lower ;an
Clean Air ;ilter
'@,CAT%O8 : Air Conditioning Com-ressor
Camry Hybrid
Handle electrical s#pply -orange cable. to !ompressor ;rom the
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Handle electrical s#pply -orange cable. to !ompressor ;rom the
0nverter with care as high voltage may be present)
The ir !onditioning !ompressor has a dedicated inverter to
convert 2! Battery Voltage to !)
,S27 com-ressor
,lectric Com-ressor Construction
=0+ E later 'rius E Highlander Hybrid
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)rushless 5otor
*ariable Scroll
;i&ed Scroll
Oil Se-arator
Discharge 'ort
5otor
Sha(t
A6C %n"erter
,S1? com-ressor ,S27 com-ressor
,S1+ Com-ressor Construction
2010 'rius
A6C %n"erter
/DC ACScroll Ty-e
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1?071 Toyota Hybrid System
Oil
Se-arator
/DC AC
DC 20143 *
y-
Com-ressor
Caution# 8se only 12%% type compressor oil)
)rushless
5otor
Solar *entilation System E @emote Air Conditioning
2010 'rius
Solar Ventilation System can operate inde;initely
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as long as the operating conditions are met
regardless o; ambient air temperat#re) ,emote ir !onditioning System will operate ;or
approximately 4 min#tes)
Solar *entilation System @emote Air Conditioning System
Solar *entilation System Com-onents
2010 'rius
6 Cells
5oonroo( Solar
5odule
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6Cell 6Cell
s
A6C Am-li(ier
Solar *entilation ,C
)lower
5otor
Air %nlet Control
Ser"o 5otor
Air Outlet Control
Ser"o 5otor
)lower 5otor @elay
*entilationSwitch
5odule
'recaution# Solar *entilation System
2010 'rius
CAT%O8A Per;orming repairs with the solar ventilation
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CAT%O8A Per;orming repairs with the solar ventilation
switch O1 may ca#se the blower motor to operate#nexpectedly9 res#lting in vario#s ha:ards)
Ti-sA
T#rn the solar ventilation switch
O// when servicing)
!over the entire solar panel to
block s#nlight)
@emote Air Conditioning
2010 'rius
!ools the cabin be;ore entering vehicle)
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A6C System
%ress
' (ol)
8se C! switch on the remote to activate)
'@,CAT%O8# @emote Air Conditioning
2010 'rius
Fhen activated9 0$ relays are t#rned O1)
T th i it h = h dli ht di it h O//
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'ower'ower
H* )attery
T#rn the wiper switch = headlight dimmer switch O//)
Store the key sec#rely so that no one cannot operate theremote C! switch)
'lasmaclusterT5 enerator
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'ositi"e and
8egati"e %ons
+
-
-
-
+ +
+
-
-
-
+
+
'lasmacluster
enerator
2010 'rius
Camry Hybrid
,Nector Cycle System /,CS
2010 'riusCa-illary
Tube,Nector
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Condenser
,&-ansion
*al"e
,Nector
Ca-illary Tube
,CS ,"a-orator
Com-ressor
-wind Side
Downwind Side
A > A Cross Section
To- Tan!
)ottom
Tan!
A
A
,"a-orator
/-wind Side
,"a-orator
/Downwind Side
,Nector Cycle System /,CS
2010 'rius
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1B1071 Toyota Hybrid System
To Evportor
*+p,in) i)e.
,Nector
/rom Evportor
*Do,n,in) i)e.
/rom Epnsion
Vlve
8ole
Di((user
'ortion
Vcuum5i&ing
'ortion
Cabin Air ;ilter 5aintenance
2010 'rius
Vehicles with Solar Ventilation System
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re>#ire more ;re>#ent cabin air ;ilter
maintenance as ;ollowsA
Proced#re Fitho#t Solar Ventilation With Solar *entilation
!lean Every %(9777 miles ,"ery 10000 5iles
,eplace Every 479777 miles ,"ery 20000 5iles
Wor!sheet .
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,'S A6C )ra!es
Acti"e Tests
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)ody ,lectrical
E 5ulti-le&Communication
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Automatic Headlight )eam $e"el
=0+ > =0B 'rius
Ser"ice Ti- * 0nitiali:e system a;ter repair
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*ehicle S-eed Signal
Combination 5eter
5aster Warning $ight
Headlight $e"eling
Actuator
Headlight )eam
$e"el Control
,C
@ear Height
Control Sensor /$H
Automatic Headlight )eam $e"el
=0+ > =0B 'rius
Ser"ice Ti- : %nitialiation
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0nitiali:e this system when yo# reinstall or replace the;ollowing itemsA
,einstall Height !ontrol Sensor
S#spension System
,eplace Height !ontrol Sensor
S#spension System
Headlight Beam Devel !ontrol E!8
5ain )ody ,C
2010 'rius
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5ain )ody ,C
J/B
Munction )loc!
'ainted Wire Harness
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;ront DoorWire Harness
'ainted only near
the connectorColor /Color Code
)lac! /)@ed /@
)lue /$
reen /
ellow /
)rown /)@
*iolet /*
White:)lac! /W:)
$ight reen /$
'in! /'
S!y )lue /S)
I,8D 5odule ? 5ulti-le&J
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eneral 5aintenance
Hybrid *ehicle Ser"ice S-eci(ications
01 > 0 'rius 0+ > =0B 'rius 10 E later'rius
Highlander Camry
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8otes#
%) 8sing a higher octane ;#el may prevent normal engine operation)
+) 8sing a di;;erent oil viscosity -s#ch as %7F*47. can ca#se oil to splash #p into the intake mani;old)4) +77% model speci;ies P0 Service JSQ)L +77+ and newer models speci;y P0 Service JSDL
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Pan gasket PC1 is &7
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This slide is hidden4 %t does not a--ear in the slide show4 %ts
-ur-ose is to create an e&tra -age (or handboo! te&t4
'rius : Tire E Wheel
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M Extra load carrying capacity -KD. m#st be #sed
MM option
=01 > =0 'rius
+77%*+774A P%'(C(,%< 6
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$ead:calcium Alloy
01 >0 'rius 0+ > =0B 'rius
,e;er to ,epair "an#al ;or systems that m#st be initiali:ed with a
battery disconnect)
Ser"ice : Au&iliary )attery
2010 'rius
2o 1OT per;orm a >#ick charge)
,eplace with dedicated battery only -S
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,eplace with dedicated battery only -S
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=10 E later 'rius
8egati"e Mum-er Cable
'ositi"e Mum-erCable
,mergency Sto- E Start ;unction
2010 'rius
0; vehicle does not appear to ,E23 O//9 change
Power so#rce mode
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Power so#rce mode
%( -ar!ing loc! actuator
mal(unctions it cannot shi(t
-osition into '
*ehicle
Sto--ed
'ar!ing )ra!e is
a--lied
'ower Source 5ode O;; is -ossible
'ower Source 5ode
O;; is not -ossible
READY
)attery Ser"ice
5odel Au&iliary )attery )attery Charger
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7% @ 74 Pri#s S4
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-ur-ose is to create an e&tra -age (or handboo! te&t4
,mergency @es-onse uide
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www)techin;o)toyota)com
I,8D 5odule B eneral Ser"iceJ
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