TOYOTA PRIUS 2001 Service Repair Manual

HV008±02
B12008
2 3 4
5 6 7 86 1
A BC
D
1 2 3
4 52
3 4
5 6 7 81
61 2 3
4 5
HV±14
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
1344 Author: Date:
2001 PRIUS (RM778U)
CONVERTER AND INVERTER ASSEMBLY
ON±VEHICLE INSPECTION
1. INSPECT INVERTER
(a) Turn the IG switch OFF and disconnect the 4 connectors.
(b) Apply battery positive voltage to connector B terminal 5 (IGCT) on the inverter side through a fuse, and
battery negative voltage to connector B terminal 6 (GND).
(c) Measure the voltage and resistance between each terminal shown below and ground.
TerminalMeasuring ConditionSpecification
A, 5 (G ± INVT)
D, 5 (M±INVT)±Approx. 2 ± 4.5 V
C, 5 (VB)±Approx. 0.5 ± 4 V
A, 4 (G ± SDOWN)
D, 4 (M ± SDOWN)Apply battery positive voltage to terminal through the resistance of 1 kW.Approx. 5 ± 6 V
B, 8 (G ± FINV)
C, 8 (M ± FINV)
B, 7 (G ± SINV)
C, 7 (M ± SINV)
Connect the terminal to connector B terminal 6 through the resistance of 10 kW.7 ± 12 V approx. 0.2 sec.
A, 1 (G ± UU)
A, 2 (G ± VU)
A, 3 (G ± WU)
D, 1 (M ± UU)
D, 2 (M ± VU)
D, 3 (M ± WU)
Connect the terminal to connector B terminal 6 through the resistance of 1 kW.Approx. 6 ± 8 V
B, 1 (G ± IVA)
B, 2 (G ± IWA)
B, 3 (G ± IVB)
B, 4 (G ± IWB)
C, 1 (M ± IVA)
C, 2 (M ± IWA)
C, 3 (M ± IVB)
C, 4 (M ± IWB)
±Approx. 0 V
B, 6 (GND)
A, 6 (G ± GINV)
D, 6 (M ± GINV)
±Continuity
C, 6 (CVRSW)Install a cover for the connecting part of the power cable for the MG1 and MG2.Continuity

B12009
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±15
1345 Author: Date:
2001 PRIUS (RM778U)
2. INSPECT CONVERTER
(a) Function check
Measure the voltage of an auxiliary battery terminal when
the ºREADYº lamp is OFF and ON.
READY lamp is OFF: Approx. 12 V
READY lamp is ON: Approx. 14 V
(b) Output current check
(1) Disconnect the MG2 power cable from the inverter
(See page HV±18).
(2) Install AC/DC 400 A probe to the wire harness of the
IP connector of the converter.
(3) Connect the MG2 power cable to the inverter (See
page HV±22).
(4) With the READY lamp ON, operate electric devices
one by one and measure the output current.
Standard: 100 A or less
HINT:
If more than 100 A is shown momentarily, check for the follow-
ings.

Ground short of electric device.

Overload caused by installation of excessive device.

PTC heater operation.

HV009±01
B11975
Wiper Arm and Blade Assembly
Wiper Motor
w/ Wiper Link
Cowl Top Ventilator
Louver
N´m (kgf´cm, ft´lbf) : Specified torque
8.0 (82, 71 in.´lbf)
Hood to Cowl Top SealCowl Top Panel
Power Cable Connector
Converter
Connector
Inverter
Connector Inverter Terminal
Cover

Gasket
Converter & Inverter
Assembly
MG1 Power CableConnector CoverCircuit Breaker Sensor
Water HoseWater Hose
20 (204, 15)
21 (214, 15)8.0 (82, 71 in.´lbf)
7.0 (71, 62 in.´lbf)MG2 Power Cable
8.0 (82, 71 in.´lbf)
19.5 (199, 14)

Non±reusable part HV±16
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
COMPONENTS

B11976
Non±reusable part
8.0 (82, 71 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torqueWater Hose
25 (255, 18)
25 (255, 18)
25 (255, 18)
BracketBracket
Bracket
O±ring Inverter Reservoir Tank
8.0 (82, 71 in.´lbf)

Gasket
2.5 (25, 22 in.´lbf)Upper Inverter Cover






± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±17
2001 PRIUS (RM778U)

HV00A±01
B11977
B11979
B11980
HV±18
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE SERVICE PLUG (See page HV±1)
2. DRAIN HV COOLANT (See page HT±6)
3. REMOVE COWL TOP PANEL (See page BO±31)
4. VERIFY 0 V
NOTICE:

Before starting step (a), 5 minutes or more should be
passed after removing the service plug.

Be careful to prevent foreign matter from entering the
inside of connector cover.
(a) Disconnect the connector of the battery power cable and
insulate it with packaging tape.
(b) Using a torx socket wrench (T30), remove the 4 screws
and inverter terminal cover.
(c) Using a torx socket wrench (T40), remove the 2 screws,
circuit breaker sensor and connector cover.
HINT:
Slide the connector cover to disconnect the circuit breaker sen-
sor connector.
(d) Using a voltmeter, measure the voltage between termi-
nals of 3 phases (U±V, V±W, U±W) and each terminal and
body ground to verify them to be approx. 0 V.
5. REMOVE CONVERTER & INVERTER ASSEMBLY
(a) Remove the 6 bolts and 3 power cables for MG2.
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(b) Remove the 3 bolts and power cable for MG1.
NOTICE:

Remove the power cable for MG1 together with con-
verter & inverter assembly.

Be careful to prevent foreign matter from entering the
inside of connector cover.
(c) Remove the bolt and ground cable.

B11978
Water
HoseWater
Hose
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±19
2001 PRIUS (RM778U)
(d) Disconnect the 3 water hoses from the converter & invert-
er assembly.
(e) Remove the 4 bolts and converter & inverter assembly.

HV00D±01
B11978
B11980
B12004
B11979
A
A
AB
B
B
B12005
HV±22
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL CONVERTER & INVERTER ASSEMBLY
(a) Install the converter & inverter assembly with the 4 bolts.
Torque: 21 N´m (214 kgf´cm, 15 ft´lbf)
(b) Connect the 3 water hoses to the converter & inverter as-
sembly.
(c) Connect the 4 connectors.
(d) Connect the 2 power cable connectors.
(e) Install the ground cable to the radiator upper support.
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
(f) Install the power cable for MG1 with the 3 bolts.
Torque: 7.0 N´m (71 kgf´cm, 62 in.´lbf)
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(g) Install the connector cover and circuit breaker sensor with
the2 screws.
Torque: 20 N´m (204 kgf´cm, 15 ft´lbf)
(h) Connect the connector for circuit breaker sensor.
(i) Install the 3 power cables for MG2 with the 6 bolts.
Torque:
Bolt A: 19.5 N´m (199 kgf´cm, 14 ft´lbf)
Bolt B: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(j) Install the gasket and inverter terminal cover with the 4
screws.
Torque: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
2. INSTALL COWL TOP PANEL (See page BO±31)
3. INSTALL SERVICE PLUG (See page HV±1)
4. FILL WITH HV COOLANT (See page HT±6)

± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±23
2001 PRIUS (RM778U)
5. OPERATION AFTER REPLACING CONVERTER & IN-
VERTER ASSEMBLY
Even if the master warning light is not lit, clear DTC using a
TOYOTA hand±held tester. When replacing a converter & in-
verter assembly of the vehicle in which no error occurs, also
clear DTC using a TOYOTA hand held tester.
HINT:
When a TOYOTA hand±held tester cannot be used, disconnect
the auxiliary battery for 1 min. or more and connect it again.
6. CHECKING AFTER REPLACING CONVERTER & IN-
VERTER ASSEMBLY
Depressing the accelerator pedal to a degree of 50 %, increase
the speed up to approx. 15 km/h 3 or 4 times to check that there
is no problem in the inverter operation.

HT003±01
D09721
D09722
D09723O±Ring
D09724
± HYBRID TRANSAXLEOIL PUMP ASSEMBLY
HT±3
1376 Author: Date:
2001 PRIUS (RM778U)
OIL PUMP ASSEMBLY
ON±VEHICLE REPAIR
1. REMOVE ENGINE UNDER COVER LH
2. REMOVE OIL PUMP
(a) Remove the plug.
(b) Remove the O±ring from the plug.
(c) Remove the 5 bolts and oil pump cover.
(d) Remove the O±ring.
(e) Remove the oil pump driven rotor and drive rotor.

D09725
D09724
D09723
O±Ring
D09722
D09721
HT±4
± HYBRID TRANSAXLEOIL PUMP ASSEMBLY
1377 Author: Date:
2001 PRIUS (RM778U)
(f) Remove the oil pump drive shaft.
3. INSTALL OIL PUMP
(a) Apply ATF to each sliding part.
(b) Install the oil pump drive shaft.
(c) Install the oil pump driven rotor and drive rotor.
(d) Install a new O±ring.
(e) Apply liquid sealer to 2 or 3 threads of the bolt end.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Install the oil pump cover with the 5 bolts.
Torque: 5.5 N´m (56 kgf´cm, 49 in.´lbf)
(g) Install a new O±ring and the plug.
Torque: 7.35 N´m (75 kgf´cm, 65 in.´lbf)
4. INSTALL ENGINE UNDER COVER LH