USB TOYOTA PRIUS 2001 Service Repair Manual

2001 PRIUS (EWD414U)
TOYOTA HYBRID SYSTEM
HYBRID VEHICLE CONTROL ECUA H10 , H11
CB, H12
E , H13
D , H14
W± BW± B HTB± BTH+
18 D
G
14
HVO+ HVO±22
R
D 17BTH±
30 D
V
16
HVI± HTB+
20 D
LG
24
HVI+ B 14 B15
1
2
G±R
G±R BR±B CIRCUIT BREAKER SENSOR C 3
AS1G AS1
BRAKE ECU B1 1
GR± B
V± Y
GR
O
LG±B
L±O
LG
P
Y± B
L±W
L
LG±R
Y
P±L
G
L±R
G± W
R
W
L±B
14 2 15 3 16 4 17 5 18 6 7 20 8 21 9 22 10 23 11 24HYBRID VEHICLE BATTERY
BUSBER MODULED 10TC
D 21SIL
D 9WF SE
ID1 2ID11 ID1 10CE
E
13 15C
E
P
P±B P±BY Y
P±B P
P±B
W± L W±L
EJUNCTION
CONNECTOR J1 6
TC WF SEE 10HAI
Y±R
E 9HAO
Y±R12
OP28
OP3JUNCTION
CONNECTOR J26 W±GW±G
W
1234
L
L
B
B
W
W
5
W
7
SIL
O(
*2) O(
*2)
A 1B 1
SERVICE PLUG
O
(
*2)O
(
*2)
HYBRID VEHICLE BATTERY
BUSBER MODULESENSOR
O O
(
*2)
(
*2)
HYBRID VEHICLE
BATTERYB H16 , H17A
BATTERY ECUB B17 , B18A
W
DATA LINK
CONNECTOR 3 D 2

2001 PRIUS (EWD414U)
M OVERALL ELECTRICAL WIRING DIAGRAM
23 24
22 21
1 PRIUS (
Cont' d)F A
B
BB
BA BA 4IA1 G± Y
L±R
5IH1 3D 7B
1A22
222 1
5 3
9B 2B 8B
BI Left s ide of
rear pillar2 1
M2 1
5 3
IECowl si de
panel LH 7IH1
W±B
TOYOTA Hybrid System
H10 H11, CA BE, H13 , H12 D, H14
HYB RI D V EHI CLE CONTROL ECU
34
BA
A 21
BA
JUNCTI ON
CONNE CTORB A J 2 J 3,
B1 7 B18,
BATTERY ECUABLG±R MRE L BATT
G±Y G±YG± Y G± Y
G±Y
G±Y W± G
G± YL L
LG±RL±B L±R W± B W± BW±B W±B
W± B L±B L±B
L W± B L±R L±R
J32
JUNCTI ON
CONNECTORJ 7
J UNCTI ON
CONNE CTOR
J 1
J UNCTI ON
CONNE CTOR
IGCT
REL AY
B19
BATTERY FAN
RELAY W±G
C
O
V± Y
14 2GR±BGR
15
O3
LG±B16
L±O4
LG17
P5
Y± B18
L±W6
L7
LG±R20
Y8
P± L21
G9
L±R22
G±W10
R23
W11
L±B24 HYB RI D VE HI CL E BA TTERY
BUSBER MODULE
L1
L2
B3
B4
W5
W6
R7
R8
G9
G10 O O
(
*2) (
*2)SERVICE PLUG O(
*2)
E DO(
*2)
1A1B
HYBRI D VEHI CLE BATTERY
BUSBER MODUL ESENSOR
O
(
*2)
HYBRI D VEHI CL E BATTERYB A H16 H17,
* 2 : High Voltage(
273. 6V)
ECEngine
compartment
leftW± BA B1 5
BATTERY BLOWER
MO TOR
B16
BAT TERY BLOWER
MOTOR CONTROL LER

SS1HI±01
± SERVICE SPECIFICATIONSHYBRID VEHICLE CONTROL
SS±21
2001 PRIUS (RM778U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Battery module x Battery carrier4.04035 in.´lbf
Battery clamp bolt x Battery carrier2323016
RH battery bracket x Battery carrier2323016
Battery ECU x Battery carrier3.33329 in.´lbf
Busber module x Battery module6.06153 in.´lbf
Power cable x SMR5.05044 in.´lbf
Service plug assembly x Battery carrier6.06153 in.´lbf
Battery cover x Battery carrier Bolt A
(See page HV±9) Bolt B
Bolt C
Screw18
8.0
7.0
6.0185
80
70
6113
71 in.´lbf
62 in.´lbf
53 in.´lbf
Battery bracket1818513
HV battery x Body1818513
Battery carrier catch bracket x Battery bracket8.08071 in.´lbf
Bracket x Converter & Inverter assembly2525518
Upper inverter cover x Converter & inverter assembly2.52522 in.´lbf
Inverter reservoir tank x Converter & inverter assembly8.08271 in.´lbf
Converter & inverter assembly x Body2121415
Ground cable x Radiator upper support8.08271 in.´lbf
Power cable for MG1 x Converter & inverter assembly7.07162 in.´lbf
Connector cover x Converter & inverter assembly2020415
Power cable for MG2 x Converter & inverter assembly Bolt A
(See page HV±22) Bolt B19.5
8.0199
8214
71 in.´lbf
Inverter terminal cover x Converter & inverter assembly8.08271 in.´lbf
HV water pump x Body7.07062 in.´lbf
Inverter radiator x Body8.08271 in.´lbf
Water temperature switch x Inverter radiator7.47565 in.´lbf
Blower assembly x Body5.05144 in.´lbf
Lower quarter ventilator duct x Body4.04135 in.´lbf
Inner ventilator duct x Body4.04135 in.´lbf
HV ECU x Body6.06053 in.´lbf

± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±339
2001 PRIUS (RM778U)
13 Is DTC P3009 of battery ECU being output?
PREPARATION:
(a) Under step 11 condition, disconnect the HV connector from the battery ECU.
(b) Connect the negative terminal of the auxiliary battery (with the service plug removed).
(c) Turn the ignition switch ON (not ST) and clear the DTC.
HINT:
When the ignition switch is turned ON, DTC P3140 is stored in the HV ECU. This happens because the ser-
vice plug is removed, so continue the operation.
CHECK:
Check that DTC P3009 is detected.
YES Replace the HV battery ECU.
NO
14 Check insulating resistance of wire harness for module voltage detection.
PREPARATION:
(a) Under step 12 condition, turn the ignition switch OFF and disconnect the negative terminal of the auxil-
iary battery.
(b) Remove the 36 nuts and the busbar module on the battery rear side.
CHECK:
Using a megger (500V), measure the insulating resistance between the connector terminal of the wire har-
ness for the removed module's voltage detection and body ground.
OK:
Insulating resistance: 10 MW or more
NG Replace the HV battery assembly.
OK
Replace the HV battery ECU.

A14077
Battery ECU
GR ± B Busbar Module
14
V ± Y 2
GR 15
O3
LG ± B 16
L ± O 4
LG 17
P5
Y ± B 18
L ± W 6
L7
LG ± R 20
Y8
P ± L 21
G9
L ± R 22
G ± W 10
R23
W11
L ± B 24VBB1
VBB2
VBB3
VBB4
VBB5
VBB6
VBB7
VBB8
VBB9
VBB10
VBB11
VBB12
VBB13
VBB14
VBB15
VBB16
VBB17
VBB18
VBB19
GBB19 DI±344
± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
2001 PRIUS (RM778U) 4/27/01
DTC P3030 Battery Voltage Detective line Snapped
CIRCUIT DESCRIPTION
A voltage sensor set in a busbar module circuit measures a voltage of a pair of battery modules and sends
signals to the battery ECU.
DTC No.DTC Detecting ConditionTrouble Area
P3030Open in battery voltage detective line

Battery ECU

Open in battery voltage detective line

Wire harness, Busbar module
WIRING DIAGRAM
DI82D±01

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

± DIAGNOSTICSHV BATTERY CONTROL SYSTEM
DI±347
2001 PRIUS (RM778U)
6 Continuity check of the busbar module.
NG Replace the busber module
(See page IN±41).
OK
Replace the battery ECU (See page IN±41).

B11984N´m (kgf´cm, ft´lbf) : Specified torque
18 (185, 13)
Battery Cover
Busbar Module Protector
Busbar Module
Battery Hose
Service Plug
Assembly
Battery ECU
SMR Battery Clamp Bolt
RH Battery Bracket
HV Battery
Thermistor
Battery Carrier Battery Module
Busbar Module Protector
x38
x38
38 (390, 28)
Service Plug Wire Harness Protector
Busbar Module
38 (390, 28)
6.0 (61, 53 in.´lbf)
8.0 (80, 71 in.´lbf)
6.0 (61, 53 in.´lbf)
SMR Cover
5.0 (50, 44 in.´lbf)
5.0 (50, 44 in.´lbf)
3.3 (33, 29 in.´lbf)
5.0 (50, 44 in.´lbf)
5.0 (50, 44 in.´lbf)
± HYBRID VEHICLE CONTROLHV BATTERY
HV±3
1333 Author: Date:
2001 PRIUS (RM778U)

HV004±01
B11963
B11964
B11965
± HYBRID VEHICLE CONTROLHV BATTERY
HV±5
2001 PRIUS (RM778U)
DISASSEMBLY
1. REMOVE BATTERY MODULE SET BOLT
Turn the battery assembly upside down, remove the 76 battery
module bolts.
NOTICE:
When turning it over, prevent the flange from being de-
formed.
HINT:
When not removing a battery module, skip the operation of step
1.
2. REMOVE BATTERY COVER
Remove the 12 bolts, screw and battery cover.
3. REMOVE SERVICE PLUG
(a) Remove the rear RH and LH busbar module protectors.
(b) Remove the 2 nuts for busbar module.
(c) Remove the nut and wire harness protector.

B12006
B11966
B11967
B11968
B11969
HV±6
± HYBRID VEHICLE CONTROLHV BATTERY
2001 PRIUS (RM778U)
(d) Remove the 3 bolts and service plug assembly.
4. REMOVE POWER CABLE FOR SMR
(a) Remove the front RH and LH busbar module protectors.
(b) Remove the 2 nuts, and disconnect the power cable from
the front busbar module.
(c) Remove the SMR cover from the SMR.
(d) Remove 2 bolts, and disconnect the power cable for
SMR.
5. REMOVE SMR
(a) Using the service plug, turn the interlock counterclock-
wise to unlock.
NOTICE:
When the interlock is damaged, be sure to replace it with
new one.
(b) Remove the 3 bolts and SMR.
6. REMOVE HV BATTERY THERMISTOR
7. REMOVE BATTERY ECU
(a) Disconnect the connector.
(b) Remove the 2 bolts and battery ECU.