engine TOYOTA PRIUS 2001 Service Repair Manual

A14081
AM
A14082
Engine Room J/B
HV Fuse
DI±324
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using a TOYOTA hand±held tester or OBD II scan tool. Because freeze frame data
records the battery condition when the malfunction is detected. When troubleshooting, this is useful for
knowing the battery condition.
1 Check voltage between terminal AM of Battery ECU connector and body ground.
PREPARATION:
Remove the luggage trim.
CHECK:
Measure the voltage between terminal AM of the Battery ECU
connector and body ground.
OK:
Voltage: 9 ± 14 V
OK Check and replace Battery ECU (See page
IN±41).
NG
2 Check HV fuse of engine room J/B.
PREPARATION:
Remove the HV fuse from the engine room J/B.
CHECK:
Check the continuity of the HV fuse.
OK:
Continuity
NG Check for short in all harness and components
connected to HV fuse.
OK
Check and repair harness or connector be-
tween battery and HV fuse, and HV fuse and
Battery ECU (See page IN±41).

± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±341
2001 PRIUS (RM778U) 4/27/01
DTC P3011±P3029 Battery Block # Malfunction
CIRCUIT DESCRIPTION
Internal resistance of each battery module is measured, detecting battery deterioration for each block, 1 to
19. Nineteen blocks of battery modules are arranged in the order of 1 to 19 from the ECU side.
DTC No.DTC Detecting ConditionTrouble Area
P3011±P3029Battery internal resistance is abnormal.
Battery ECU

Battery pack
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P3011±P3029) being outputs?
YES Go to relevant DTC chart.
NO
2 Check that the block voltage during charging/ discharging.
PREPARATION:
(a) To ensure safety, conduct this test in a wide, clear level area which provides good traction.
(b) Turn ON the ºREADYº light.
(c) Warm up the engine and turn off the A/C switch.
(d) Fully apply the parking brake and chock the 4 wheels.
(e) Connect a TOYOTA hand±held tester to DLC3 and select HV BATTERY and then CURRENT DATA.
(f) Show voltage of the block corresponding to the DTC and other block (any block except the above±
mentioned block).
CHECK:
(a) Keep your left foot pressed firmly on the brake pedal and shift into the R position.
(b) Confirm the engine stopped in the R position. Step on the accelerator pedal until the engine starts,
stepping on the brake pedal firmly.
(c) Release the accelerator pedal when the engine starts. At the same time, monitor the change of the
voltage before engine starting (during discharging) and after engine starting (during charging).
DI82C±01

A16881
Voltage
Other block voltage
Voltage of the block
corresponding to the DTC
Discharging (engine stops) Charging (engine starts)A: 0.3 V or more A
B: 0.3 V or more B
Time
DI±342
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U)
OK:
Before or after switch±over from discharging to charging, the relationship of the voltage size
are reversed and the difference of the voltage is 0.3 V ore more.
OK Go to step 5.
NG
3 Check that the HV battery blocks voltage swings at stall test.
PREPARATION:
(a) To ensure safety, conduct this test in a wide, clear level area which provides good traction.
(b) Turn ON the ºReadyº light.
(c) Warm up the engine and turn off the A/C switch.
(d) Fully apply the parking brake and chock the 4 wheels.
(e) Connect a TOYOTA hand±held tester to DLC3 and select HV BATTERY and then CURRENT DATA
to show ºBAT BLOCK MIN Vº and ºBAT BLOCK MAX Vº on the TOYOTA hand±held tester.
CHECK:
(a) Keep your left foot pressed firmly on the brake pedal and shift into the R position.
(b) Stepping on the brake pedal, release the accelerator pedal during the engine moving and step on the
accelerator pedal during the engine stopping.
(c) Continue STEP (b) for more than 20 min. and monitor the swing and the difference of the voltage be-
tween the data MAX V and MIN V.

A16880
The difference of the voltage
between the date VMAX and VMIN
SwingVMAX data
The engine start Test startTime
Voltage
Swing
Swing
SwingVMIN data
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±343
2001 PRIUS (RM778U) 4/27/01 OK:
Standard voltage swing: Less than 2 V
NG Replace the battery ECU (See page IN±41).
OK
4 Check the difference of the voltage between the data V MAX and V MIN.
Standard voltage difference: Less than 1.2 V
YES Replace the battery ECU. (See page IN±41).
NO
5 Replace the battery pack assembly, and initialize the battery ECU by performing
an active test.

± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±345
2001 PRIUS (RM778U)
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P3030) being outputs?
YES Go to relevant DTC chart.
NO
2 Check voltage of battery block 1 to 19.
CHECK:
Connecting a TOYOTA hand±held tester, check the ECU data.
HINT:
Nineteen blocks of battery modules are arranged in the order of 1 to 19 from the battery ECU side.
OK:
Standard voltage: 2V or more
OK Go to step 4.
NG
3 Check that the HV battery blocks voltage swings at stall test.
PREPARATION:
(a) To ensure safety, conduct this test in a wide, clear level area which provides good traction.
(b) Turn ON the ºREADYº light.
(c) Warm up the engine and turn off the A/C switch.
(d) Fully apply the parking brake and chock the 4 wheels.
(e) Connect a TOYOTA hand±held tester to DLC3 and select HV BATTERY and then CURRENT DATA
to show ºBAT BLOCK MIN Vº and ºBAT BLOCK MAX Vº on the TOYOTA hand±held tester.
CHECK:
(a) Keep your left foot pressed firmly on the brake pedal and shift into the R position.
(b) Stepping on the brake pedal, release the accelerator pedal during the engine moving and step on the
accelerator pedal during the engine stopping.
(c) Continue STEP (b) for more than 20 min. and monitor the swing and the difference of the voltage be-
tween the data MAX V and MIN V.

A16880
The difference of the voltage
between the date VMAX and VMIN
SwingVMAX data
The engine start Test startTime
Voltage
Swing
Swing
SwingVMIN data
DI±346
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U) 4/27/01
OK:
Standard voltage swing: 2 V or more
NG Replace the battery ECU (See page IN±41).
OK
4 Check tightening condition of busbar module of block and correct if necessary.
OK:
The nut is not loosened.
Torque: 6 N´m (61 kgf´cm, 4.4 ft´lbf)
NG Tighten the nut.
OK
5 Check if busbar module connector is properly connected.
NG Connect properly, repair or replace.
OK

A14079
Battery ECU
B19
Battery Fan Relay
B15
Battery
Blower
Motor
B16
Battery Blower
Motor Controller
Fusible Link Block No. 1
Fusible Link Block No. 2BATT FAN Engine Room J/B
Battery
BI BJ32
J/C L ± R L ± B LG ± R
L ± B L ± R
L ± R
MAINW ± B
W ± B B ± G
BJ J33 BJ32 C
1
F181
F131
F122
1B 8
1J7
IH13 1
5 2
L1
2
L3
1 429
B182
B188
B18
W ± B
W ± B B
13
J/CFCTL1
VM
SI
VM SI
+B E
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±351
2001 PRIUS (RM778U)
DTC P3077 Battery Cooling Fan Motor Circuit Malfunc-
tion
CIRCUIT DESCRIPTION
To control rise in battery temperature during driving and charging, the battery fan operation is controlled in
3 levels depending on battery temperature.
DTC No.DTC Detecting ConditionTrouble Area
P3077
Electric error in battery cooling fan motor circuit continues for
10 sec.
(2 trip detection logic)
Battery blower motor

Battery fan relay

Battery blower motor controller

Wire harness
WIRING DIAGRAM
DI82G±01

A14084
Engine Room J/B
FAN Fuse
DI±352
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U)
INSPECTION PROCEDURE
1 Check FAN fuse of engine room J/B.
PREPARATION:
Remove the FAN fuse from the engine room J/B.
CHECK:
Check the continuity of the FAN fuse.
OK:
Continuity
NG Check for short in all harness and components
connected to FAN fuse. Check that the motor is
not locked. If locked, replace the motor.
OK
2 Check blower fan relay (See page HV±35).
NG Replace the blower fan relay.
OK
3 Check blower motor operation.
PREPARATION:
Remove the blower motor (See page HV±32).
CHECK:
Apply battery voltage to the power supply terminal of the motor, and check the fan rotation.
OK:
The fan rotates normally.
NG Replace the blower motor.
OK
Replace battery blower motor controller.

F12396
TOYOTA
Hand±held Tester
DLC3
F09750
DLC3Tc
Ts
CG
BR3904
0.13 sec. 0.13 sec.
ON
OFF DI±360
± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
2001 PRIUS (RM778U)
(g) In case of using TOYOTA hand±held tester:
Clear the DTC.
(1) Hook up the TOYOTA hand±held tester to the
DLC3.
(2) Turn the ignition switch ON.
(3) Operate the TOYOTA hand±held tester to erase the
codes.
HINT:
Please refer to the TOYOTA hand±held tester operator's manu-
al for further details.
3. SENSOR SIGNAL CHECK (TEST MODE)
HINT:
If the ignition switch is turned from ON to ACC or LOCK during
test mode, DTC will be erased.
(a) In case of not using TOYOTA hand±held tester:
Check the sensor signal.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and CG of DLC3.
SST 09843±18040
(3) Start the engine.
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit and Ts terminal circuit (See page DI±437,
DI±449).
(5) Keep the vehicle in the stationary condition and the
brake pedal in free condition for 1 sec. or more.
(6) Keeping the vehicle in the stationary condition, de-
press the brake pedal with 98 N (10 kgf, 22 lbf) or
more for 1 sec. or more.
(7) Drive vehicle straight forward.
When driving the vehicle at the speed faster than 45
km/h (28 mph) for several seconds, check that the
ABS warning light comes off.
HINT:
There is a case that the sensor check is not completed if the ve-
hicle has its front wheels spun or its steering wheel steered dur-
ing this check.

F12671
Brake ECU
SFRH
SFRR
SFLH
SFLR Engine Room
R/B No. 3
19
5 1121
4 W±R
2 1 4
3
7 14
IER1+
SR
8 W±B
F102
Brake Actuator 1
A
Battery10R±W
Y±B
G±W
G±O G±B
B39
32 5
12
R±Y ABS No. 1
BS
SFRR
SFLH
SFLR
SRRH
SRRR
SMC1
SS J1
J/C1
4 W
3 FL
Block
No. 1 2
1
B3 B3 B2
B3 B2 B3 B3B3B11 IA2
R±L R±G R±B SFRH
SMC2Y±B
Y±B
3
B10SRRH
SRRR
SMC1
SS SMC2 9
B10B10 B10B10 B10B10 B10B10 B10 B±L7
3
3
3
3 36
J7
J/C
W±B AA
B2 3
3Engine
Room
R/B No. 3
F131
1
B±G
1
FL
Block
No. 2ABS Solenoid Relay
R
DC/DC
MAIN
± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
DI±379
2001 PRIUS (RM778U)
WIRING DIAGRAM