brake rotor TOYOTA PRIUS 2001 Service Repair Manual
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Page 325 of 1943
THS (TOYOTA HYBRID SYSTEM)27
THS CONTROL SYSTEM
1. General
The THS control system contains the following components:
HV (Hybrid Vehicle
Control) ECU
Controls the MG1, 2 and the engine according to the demand torque,
regenerative brake control and the SOC (state of charge) of HV battery. These
factors are determined by the shift position, the degree which the accelerator
is depressed, and vehicle speed.
ECM
ControlThe HV ECU receives engine status data (rpm, torque) from the ECM and
determines the engine demand torque.
Moreover, engine stop and fuel cut signals are sent according to the driving
conditions.
In addition, the vehicle speed signal received from the combination meter is
also sent.
BRAKE
ECU
ControlThe HV ECU receives data corresponding to the total braking force needed.
The HV ECU transmits the regeneration brake demand torque valve, as well
as the regeneration brake execution torque valve.
Inverter
(for MG1,
MG2)
ControlThe HV ECU sends the signal to the power transistor in the inverter for
switching the U, V, W, phase of the MG1, 2 in order to drive the MG1 and 2.
Moreover, if an overheating, overcurrent or fault voltage signal is received
from the inverter, it is shut down.
ConverterWhen a malfunction is in the Hybrid vehicle control system, the HV ECU
sends a signal to the converter, and the converter is stopped.
MG1, MG2Detects the position of the rotor of the MG1, 2 and controls the current flowing
to the MG1, 2.
In addition, the temperature is detected and the maximum load is controlled.
Battery ECUReceives the SOC of the HV battery and the current value.
Airbag Sensor
AssemblyReceives the airbag deployment signal.
A / C ECUReceives the engine power rise demand (when air-conditioning is turned ON)
and the engine running demand for water-temperature maintenance.
Accelerator Pedal
Position SensorReceives the value corresponding to degree at which the accelerator pedal is
depressed.
Shift Position SensorReceives the shift position signal (P, R, N, D, B).
Cruise Control SwitchReceives the cruise control switch signal.
Stop Light SwitchReceives the brake signal.
Interlock Switch
(for Inverter Cover and
Service Plug)Verifies that the cover of both the inverter and the service plug have been
installed.
Circuit Breaker SensorThe high-voltage circuit is intercepted if a vehicle collision has been detected.
DiagnosisWhen the HV ECU detects a malfunction, the HV ECU diagnosis and
memorizes the values corresponding to the failure.
Fail-SafeWhen the HV ECU detects a malfunction, the HV ECU stops or controls the
actuators and ECUs according to the data already stored in memory.
Page 331 of 1943
THS (TOYOTA HYBRID SYSTEM)
182CH05
Stator
Rotor
Speed Sensor (Resolver)
MG1
182CH04
Stator
Rotor
Speed Sensor (Resolver)
MG2
182TH07
N.m
350
300
250
200
150
100
50
0
01000 30002000 50004000 60000 20 40
30
10 kW
Torque
Engine Speed (rpm)Output
Torque
Output
33
MG1 AND MG2 (MOTOR GENERATOR NO.1 AND NO.2)
DESCRIPTION
Both the MG1 and the MG2 are compact, lightweight, and highly efficient alternating current permanent
magnet synchronous type.
Serving as the source of supplemental motive force that provides power assistance to the engine as needed,
the electric motor helps the vehicle achieve excellent dynamic performance, including smooth start-offs
and acceleration. When the regenerative brake is activated, MG2 converts the vehicle's kinetic energy into
electrical energy, which is then stored in the HV battery.
MG1 recharges the HV battery and supplies electrical power to drive MG2. In addition, by regulating the
amount of electrical power generated (thus varying the generator's rpm), MG1 effectively controls the
continuously variable transmission function of the transaxle. MG1 also serves as the starter to start the
engine.
MG2 Specifications
TypePermanent Magnet
Motor (1CM)
Rated voltage [V]273.6
Maximum output [kW] (rpm)33 / (1040 5600)
Maximum torque [N.m (kgf.m) (rpm)350 / (0 400)
Amperage at maximum torque [A]351
Cooling systemWater-cooled
Performance Curve
Page 343 of 1943
CHASSIS ± P111 HYBRID TRANSAXLE
182CH05
Stator
Rotor
Stator
Rotor
182CH04
81
3. MG (Motor Generator) 1
The MG1 recharges the HV (Hybrid Vehicle) bat-
tery and supplies electrical power to drive the
MG2. In addition, by regulating the amount of
electrical power generated, thus varying the
MG2's speed, the MG1 effectively controls the
continuously variable transmission function of the
transaxle. Connected to the sun gear of the plane-
tary gear unit, MG1 also functions as a starter for
starting the engine.
4. MG (Motor Generator) 2
Serving as the source of supplemental motive
force that provides power assist to the output of the
engine as needed, the electric motor helps the ve-
hicle achieve an excellent dynamic performance
that includes smooth start-offs and acceleration.
Connected to the ring gear in the planetary gear
unit, MG2 is an electric motor that converts the ve-
hicle's kinetic energy that is generated through the
activation of the regenerative brake into electrical
energy, which is then stored in the HV batteries.
Page 363 of 1943
CHASSIS ± BRAKES
182CH39
182CH40
101
Specifications
Master CylinderTypeSingleMaster CylinderDiameter mm (in.)22.22 (0.87)
Brake Booster TypeHydraulic
TypeVentilated Disc
Front BrakeCaliper TypePE54Front BrakeWheel Cylinder Dia. mm (in.)54.0 (2.13)
Rotor Size (D x T)* mm (in.)255 x 22 (10.04 x 0.87)
TypeLeading-Trailing Drum
Rear BrakeWheel Cylinder Dia. mm (in.)20.64 (0.81)
Drum Inner Dia. mm (in.)200 (7.87)
Brake Control Valve TypeP & B Valve
TypeDrum
Parking BrakeSize mm (in.)200 (7.87)g
Lever TypePedal
ABS with EBDSTD
*: D: Outer Diameter, T: Thickness
FRONT BRAKE
The PE54 type brake calipers and ventilated disc
rotor have been adopted. These brake calipers are
lightweight and compact to realize excellent brake
performance.
REAR BRAKE
General
The leading-trailing type drum brakes using
drums with a 200 mm (7.87 in.) inner diameter
have been adopted.
A hydraulic system that adjusts the clearance
between the shoes and the drum has been
adopted.
Page 366 of 1943
CHASSIS ± BRAKES
182CH44
Front
Brake ActuatorRear
Hydraulic
Brake
Differential
Gear
Stroke
Simulator
Hydraulic
Adjustment Area
ABS Function AreaHydraulic
Brake
MG2
MG1Inverter
EngineHV Battery
THS (TOYOTA Hybrid System) Regenerative
Brake
Switching
Valve
Power Splitting
Device
182CH45
Combination Meter
Brake ECU
Brake Warning Buzzer
Rear Wheel
Speed Sensors
and Rotors
Hydraulic Brake Booster
(Master Cylinder Portion)
Front Wheel Speed
Sensor and Rotor
Brake Actuator HV ECU
Hydraulic Brake
Booster
Power Supply
portion
Solenoid RelayReservoir
Tank
ECMPump
Motor Relays 104
BRAKE SYSTEM
1. General
A brake system, which uses brake fluid that is stored under high pressure to assist the brake pedal effort
and to operate the ABS with EBD control and the regenerative brake cooperative control, has been adopted.
A regenerative brake system, which uses the MG2 that is used for driving the vehicle as a generator to effi-
ciently convert the energy that is created during braking, has been adopted. This system enables to collect
more driving energy by having the control to cooperate the hydraulic brake and the regenerative brake.
2. System Diagram
3. Layout of Main Components
Page 386 of 1943
CHASSIS ± STEERING
182CH69
Meter ECU
EMPS ECU
Relay
DC MotorRear Wheel Speed
Sensors and Rotors
Brake ECU Multi-information Display 124
2. Layout of Main Components
3. Function of Main Components
ComponentsFunction
St i
Torque Sensor
Detects the twist of the torsion bar, converts the torque that is applied
to the torsion bar into an electrical signal, and outputs this signal to
the ECU.
Steering
Gear
DC MotorGenerates power assist in accordance with a signal received from the
EMPS ECU.
Reduction
MechanismReduces the rotation of the DC motor and transmits it to the pinion
shaft.
EMPS ECU
Actuates the DC motor mounted on the steering gear for providing
power assist, based on the signals received from various sensors and
the rear wheel speed signal.
Meter ECUOutputs a signal for displaying the PS warning on the center display
in case of a malfunction in the system.
Brake ECURear wheel speed signals are outputted to EMPS ECU.
RelaySupplies power to the DC motor for power assist.
Multi-information DisplayDisplays the PS warning in case of a malfunction in the system.
Page 512 of 1943
S01304
MA02H±03
MA±6
± MAINTENANCEBRAKE
59 Author: Date:
2001 PRIUS (RM778U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS
(See page BR±29 )
HINT:
If a squealing or scraping noise comes from the brake during,
check the pad wear indicator to see if it is contacting the disc
rotor. If so, the disc pad should be replaced.
3. INSPECT BRAKE LININGS AND DRUMS
(See page BR±35)
Page 942 of 1943
DI±362
± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
2001 PRIUS (RM778U)
DTC of sensor check function:
Code No.DiagnosisTrouble Area
C1271/71Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor
C1272/72Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor
C1273/73Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor
C1274/74Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor
C1275/75Abnormal change in output voltage of right front speed sen-
sorRight front speed sensor rotor
C1276/76Abnormal change in output voltage of left front speed
sensorLeft front speed sensor rotor
C1277/77Abnormal change in output voltage of right rear speed
sensorRight rear speed sensor rotor
C1278/78Abnormal change in output voltage of left rear speed sensorLeft rear speed sensor rotor
C1281/81Master cylinder (M/C) pressure sensor output signals is
faultyMaster cylinder (M/C) pressure sensor
C1282/82Regulator (REG) pressure sensor output signal is faultyRegulator (REG) pressure sensor
C1283/83Front (FR) pressure sensor output signal is faultyFront (FR) pressure sensor
C1284/84Rear (RR) pressure sensor output signal is faultyRear (RR) pressure sensor
Page 943 of 1943
DI28U±10
± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
DI±363
2001 PRIUS (RM778U)
DIAGNOSTIC TROUBLE CODE CHART
NOTICE:
When removing the part, turn the ignition switch OFF.
HINT:
Using SST 09843±18040, connect the terminals Tc and CG of DLC3.
If any abnormality is not found when inspecting parts, inspect the ECU.
If a malfunction code is displayed during the DTC check, check the circuit listed that code. For details
of each code, turn to the page referred to under the ºSee pageº for respective ºDTC No.º in the DTC
chart.
DTC No.
(See Page)Detection ItemTrouble Area
C0200/31*1
(DI±366)Right front wheel speed sensor signal malfunction
C0205/32*1
(DI±366)Left front wheel speed sensor signal malfunctionRight front, left front, right rear and left rear speed sensor
Eh d i itC0210/33*1
(DI±366)Right rear wheel speed sensor signal malfunction
Each speed sensor circuit
Sensor rotor
C0215/34*1
(DI±366)Left rear wheel speed sensor signal malfunction
C0226/21
(DI±373)Malfunction in ABS solenoid (SFR) circuitSFRR or SFRH circuit
Brake actuator
C0236/22
(DI±373)Malfunction in ABS solenoid (SFL) circuitSFLR or SFLH circuit
Brake actuator
C0246/23
(DI±373)Malfunction in ABS solenoid (SR) circuitSRR or SRH circuit
Brake actuator
C0278/11
(DI±376)Open circuit in ABS solenoid relay circuitABS solenoid relay
C0279/12
(DI±376)Short circuit in ABS solenoid relay circuit
ABS solenoid relay
ABS solenoid relay circuit
C1202/58
(DI±380)Brake fluid level low
Open circuit in brake fluid level warning switch circuitBrake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit
C1211/61
(DI±382)Malfunction in linear solenoid (SLA) circuitSLA+ or SLA± circuit
Brake actuator
C1212/62
(DI±382)Malfunction in linear solenoid (SLR) circuitSLR+ or SLR± circuit
Brake actuator
C1213/63
(DI±384)Malfunction in HV ECU communication circuit
HVI+ or HVI± circuit
HVO+ or HVO± circuit
HV ECU
C1214/64
(DI±386)Malfunction in hydraulic system
Each pressure sensor
Each pressure sensor circuit
Fluid leakage
C1215/15
(DI±387)Low positive voltage of linear solenoidBattery
Ch i tC1216/16
(DI±387)High positive voltage of linear solenoid
Charging system
Power source circuit
C1217/25
(DI±373)Malfunction in regenerative solenoid (SMC1) circuitRegenerative solenoid (SMC1) circuit
Brake actuator
C1218/26
(DI±373)Malfunction in regenerative solenoid (SMC2) circuitRegenerative solenoid (SMC2) circuit
Brake actuator
Page 949 of 1943
DI7OK±01
BR3583
BR3582F00010
RotorSpeed Sensor
Magnet
To ECU
+V
±VHigh Speed
Low Speed
CoilNS
± DIAGNOSTICSANTI±LOCK BRAKE SYSTEM WITH EBD & RBS
DI±371
2001 PRIUS (RM778U)
CIRCUIT INSPECTION
DTC
C0200/31 ± C0215/34Speed Sensor Circuit
CIRCUIT DESCRIPTION
The speed sensor detects wheel speed and sends the ap-
propriate signals to the ECU. These signals are used for control
of both the ABS & EBD control system. The front and rear rotors
each have 48 serrations.
When the rotors rotate, the magnetic field emitted by the perma-
nent magnet in the speed sensor generates an AC voltage.
Since the frequency of this AC voltage changes in direct propor-
tion to the speed of the rotor, the frequency is used by the ECU
to detect the speed of each wheel.
DTC No.DTC Detecting ConditionTrouble Area
C0200/31
C0205/32
C0210/33
C0215/34
Detection of any of conditions 1. through 4.:
1. At vehicle speed of 10 km/h (6 mph) or more, pulses are
not input for 15 sec. or more.
2. While a vehicle is driven at a speed of 15 km/h (24 mph)
or more, pulse signals from the speed sensor are
instantly omitted 7 times or more.
3. While a vehicle is driven at a speed of 20 km/h (32 mph)
or more, error signals from the speed sensor are trans-
mitted consecutively 75 time or more within 5 min.
4. When the ignition switch is ON, an open circuit in the
speed sensor continues for 0.5 sec. or more.
Right front, left front, right rear and left rear speed sensor
Each speed sensor circuit
Sensor rotor
HINT:
DTC No. C0200/31 is for the right front speed sensor.
DTC No. C0205/32 is for the left front speed sensor.
DTC No. C0210/33 is for the right rear speed sensor.
DTC No. C0215/34 is for the left rear speed sensor.