charging TOYOTA PRIUS 2001 Service Repair Manual

SYSTEM INDEX
M OVERALL ELECTRICAL WIRING DIAGRAM
2001 PRIUS (EWD414U)
SYSTEMS LOCATION SYSTEMS LOCATION
ABS 19±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning 24±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Back±Up Light 6±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigarette Lighter 11±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination Meter 23±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Lock Control 15±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Tension Reducer 13±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMPS 20±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control 2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gateway System 14±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight (w/ Daytime Running Light) 4±2. . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight (w/o Daytime Running Light) 3±2. . . . . . . . . . . . . . . . . . . . . . . . .
Horn 12±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hybrid Vehicle Immobiliser System 2±16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Illumination 8±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Light 10±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Reminder and Light Reminder Buzzer 9±2. . . . . . . . . . . . . . . . . . . . . .
Light Auto Turn Off 9±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigation System 14±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Source 1~24±1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Window 18±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Fan and Condenser Fan 22±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio and Player 14±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Defogger 22±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Mirror 11±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Warning 9±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Lock 13±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRS 21±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Light 3±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight 7±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Deterrent 17±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOYOTA Hybrid System 1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Charging
* Cruise Control
* Regenerative Brake
Turn Signal and Hazard Warning Light 5±2. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper and Washer 12±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wireless Door Lock Control 16±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEW MODEL OUTLINE
Gasoline engine + AC motor = TOYOTA Hybrid System (THS)
Tremendous improvement in fuel efficiency & clean achieved!
Inverter1NZ-FXE
engine
P111 Hybrid transaxleHV battery182MO11182MO12
Hybrid transaxle
13
TOYOTA Hybrid System (THS)
The TOYOTA hybrid system has two drive sources, one is the gasoline engine and the other, the AC motor.
The power train system selects the best combination of the different characteristics of both depending on
driving conditions. Also, through the adoption of a regenerative braking system, which recovers energy
during deceleration and ªidling stopº whereby the engine is stopped during idling, we have been able to
provide for maximum energy conservation. This has resulted in a vastly superior fuel economy compared
with that of gasoline A/T vehicles of the same displacement.
Features of the System
1. Optimum distribution of drive sources
The most efficient engine operating zone is automatically selected by controlling the optimum distribution of the engine and motor
drive energy sources.
2. Reduced energy loss
The engine is automatically stopped when starting and travelling at low load to reduce fuel consumption.*1
The kinetic energy that used to be lost through engine or foot braking is recovered by the regenerative braking system and used
for recharging, thereby contributing to improved fuel efficiency. When the driver applies the brakes, the hydraulic and regenera-
tive braking systems are coordinated. In order to recover more energy, a higher proportion of regenerative braking is used.
3. Not required for recharging from an external source
The system uses MG1 (Motor Generator No.1) and MG2 (Motor Generator No.2) to maintain a constant battery charge, so unlike
an electric vehicle, recharging from an external source is not required.
*1 : In some cases, the engine does not stop, depending on the air conditioner and HV battery (Hybrid Vehicle Battery) status.
System configuration
P111 HYBRID TRANSAXLE
Fitted with built-in THS transaxle MG1 (Motor Generator No.1), MG2 (Motor Generator No.2), power spliting device and reduction
gears for the hybrid system. These function to switch engine operation to MG2 assistance, HV battery charging and power generation
for driving MG2.
Inverter
This controls the current between MG1, MG2 and HV battery and converts DC/AC power.
HV Battery (Hybrid Vehicle Battery)
This supplies power to the motor at full load or on engine stopping and stores power recovered by regenerative braking or power
generation by MG1. 228 nickel-metal hydride batteries are connected in series to obtain a voltage of 273.6 V DC.

NEW MODEL OUTLINE
182MO18
182MO19
182EG03
kW
60
50
40
30
20
10 N´m
120
11 0
100
90
80
Engine Speed (rpm) 1,000 2,000 3,000 4,000 5,000(52/4,500)
(111/4,200)
Torque
Output
15
HV Battery Charging
When high load operation is continued, the engine
does not stop to charge the HV battery even
if the vehicle is stopped, in order to keep the
HV battery charged to a given level. (when
ªREADYº light is ON.) ;however, the engine does
not charge the HV battery when the lever is
shifted into the ªNº position.
The engine speed may also be increased during normal
traveling in order to charge the HV battery.
1NZ-FXE Engine
The new Prius is fitted with a 1.5
gasoline engine which has been developed for the use with the TOYOTA
hybrid system. A mass of leading-edge technology has been implemented to achieve excellent fuel economy,
low emissions, light weight, compactness, and low vibration and noise.
Outline of the 1NZ-FXE Engine Engine performance curve
1NZ-FXE
Displacement (m
)1,497
TypeDOHC 4 valves
Bore y Stroke (mm)75.0 y 84.7
Compression ratio13.0
Maximum output [kW (HP)/rpm]52 (70)/4,500
Maximum torque [N´m (lb´ft)/rpm]111 (82)/4,200
FuelGasoline

NEW MODEL OUTLINE
MAIN EQUIPMENT
182MO20
[Information Screen]
This screen indicates the direction of energy trans-
mission. It is also possible to check the current drive
method (engine, motor or both) and status of power
generation by the engine and that of charging regen-
erative energy.
This screen indicates the average fuel consumption,
amount of recovered energy and fuel consumption for
that moment. Average fuel consumption is displayed
at 5-minutes intervals. The recovered energy display
indicates the amount of energy recovered over the past
5 minutes, with each mark representing 50Wh.
182BE36
182BE37
17
A range of features for comfort - the more you use them,
the better they get.
Multi-Information Display

The 5.8º wide touch panel type multi-information color LCD
is standard.

Energy monitor, fuel consumption and other vehicle information
screens, audio operation status and audio operation screen can
be indicated on the multi-information display. The outside tem-
perature are also indicated on the screen.
[Audio system]

An AM/FM cassette and 4-speaker system compatible with the
multi-information display has been adopted.

As the touch panel type display is used to operate the audio sys-
tem, the multi-information display simultaneously indicates the
operating status of the audio system.

The antenna provided is a collapsible style pole antenna posi-
tioned at the center of the roof.
[GPS Voice Navigation]

A GPS (Global Positioning System) voice navigation system
is optional.

The multi-information display can show the map on favorite
type among turn list, arrow display and enlarged intersection.

Using DVD (Digital Versatile Disk) as a memory source for map
data, a large quantity of information can be processed.
 Main Function of the Multi-information Display
ScreenFunction
Enlargement / reduction, rotation and move-
ment of map
Mapscreen
Indication of current position and direction of
travel
Map screen
displayCorrection of current positiondis lay(option)Setting, change and indication of route()
Voice guidance
Indication of enlarged intersections
Memory and indication of map position
Audio screenStatus of audio equipment and audio opera-
tion screen indication
InformationEnergy monitor screen indicationInformationscreenFuel consumption screen indication
Adj t tSound quality adjustment screen indicationAdjustmentscreenImage quality adjustment screen indicationscreenNo indication
On-screenAudio status indicationOn screenindicationWarning indication
Interrupt screenWarning indication
DiagnosisscreenDisplays system diagnosisscreen
displayDisplays various types of coefficient settings

ENGINE ± 1NZ-FXE ENGINE
165EG25
Camshaft
Position
Sensor
Crankshaft
Position
Sensor
Various
SensorsG2
NEECM
IGT1
IGT2
IGT3
IGT4
IGF+BIgnition Coil
(with Igniter)
No.1
Cylinder
No.2
Cylinder
No.3
Cylinder
No.4
Cylinder61

IGNITION SYSTEM
1. General
A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces
high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor.
The DIS in 1NZ-FXE engine is an independent ignition system which has one ignition coil (with igniter) for
each cylinder.
2. Ignition Coil
The DIS provides 4 ignition coils, one for each cylinder. The spark plug caps, which provide contact to the
spark plugs, are integrated with an ignition coil. Also, an igniter is enclosed to simplify the system.
3. Spark Plug
Iridium-tipped spark plugs have been adopted to realize a 60,000-mile (100,000 km) maintenance-free op-
eration. Their center electrode is made of iridium, which excels in wear resistance. As a result, the center
electrode is made with a smaller diameter and improved the ignition performance.

CHARGING AND STARTING SYSTEM
MG1 and MG2 (Motor Generator No.1 and 2) have been adopted in the charging system, and the convention-
al generator has been discontinued.
Furthermore, due to the adoption of MG1 for the starting system, the conventional starter has been discontin-
ued.

THS (TOYOTA HYBRID SYSTEM)
182TH19
EngineECMHV ECU
Shift Position Sensor
Brake ECU
HV Battery
Accelerator Pedal Position Sensor
Hybrid Transaxle Inverter with Converter
Battery ECU
SMR (System Main Relay)
Service Plug23

FEATURES OF THS
This system controls the following modes in order to achieve the most efficient operations to match the driv-
ing conditions:
1. Supply of electrical power from the HV battery to MG2 provides force to drive the wheels
2. While the tires are driven by the engine via the planetary gears, MG1 is driven via the planetary gears to
supply electricity to MG2 to drive the wheels
3. When the vehicle is decelerating, kinetic energy from the wheels is recovered and converted into electrical
energy and used to recharge the HV battery by means of MG2.
The HV ECU switches between these modes (1, 2, 1 + 2, or 3) according to the driving conditions. However,
when the SOC of the HV battery is low, the HV battery is charged by the engine by turning MG1.
As a result, it achieves far greater the fuel economy compared to conventional gasoline engine vehicles, at
a reduced level of exhaust gas emissions. Furthermore, this revolutionary powertrain has eliminated the
constraints that are associated with electric vehicles (such as their short cruising range or their reliance on
external recharging units).

LAYOUT OF MAIN COMPONENTS

THS (TOYOTA HYBRID SYSTEM) 24

MAIN FUNCTIONS OF COMPONENTS
MG1Generates high-voltage electricity by being powered primarily by the engine.
Also functions as a starter to start the engine.
Hybrid
Trans-
axle
MG2
Primarily provide additional power to the engine in order to increase the
overall drive force. During braking, or when the accelerator pedal is not
depressed, it generates electricity to recharge the HV battery (Regenerative
brake system).
Planetary
Gear UnitDistributes the engine's drive force as appropriate to directly drive the vehicle
as well as the generator.
HV Battery
Supplies electric power to the MG2 during start-off, acceleration, and uphill
driving; recharged during braking or when the accelerator pedal is not
depressed.
InverterA device that converts the high-voltage DC (HV battery) into AC (MG1 and
MG2) and vice versa (Converts AC into DC).
Converter
Drops the high-voltage direct current (DC 273.6 V) into DC12 V in order to
supply electricity to body electrical components, as well as to recharge the
auxiliary battery (12 V).
HV (Hybrid Vehicle
Control) ECU
Information from each sensor as well as from the ECU (ECM, Battery ECU,
ABS ECU) is received, and based on this the required torque and output power
is calculated.
The HV ECU sends the calculated result to the actuators and controllers.
ECMSends a throttle open command to the electronically-controlled throttle in
accordance with the engine output request factor received from the HV ECU.
Battery ECUMonitors the charging condition of the HV battery.
Brake ECU
Controls the regenerative brake that is effected by the MG2 and the hydraulic
brake so that the total braking force equals that of a conventional vehicle that
is equipped only with hydraulic brakes.
Also, the brake ECU performs the ABS control conventionally.
Accelerator PedalConverts the accelerator angle into an electrical signal and outputs it to the HVAccelerator Pedal
Position Sensor
Converts the accelerator angle into an electrical signal and outputs it to the HV
ECU.
Shift Position SensorConverts the shift lever position into an electrical signal and outputs it to the
HV ECU.
SMR (System Main
Relay)Connects and disconnects the high-voltage power circuit through the use of
a signal from the HV ECU.
Service plugShuts off the high-voltage circuit of the HV battery when this plug is removed
for vehicle inspection or maintenance.

THS (TOYOTA HYBRID SYSTEM)
Shift Position
Sensor
182TH05
Accelerator
Pedal Position
Sensor
BRAKE
ECU
Shift Position
(Main and Sub)
Accelerator Angle
(Main and Sub)
Regenerative
Request FactorHV ECUInverter
Voltage
SMR Control
MG2MG1
RPMEngine
Power
RequestCharging
Condition,
Amperage
SMRSMR
Amperage
HV
Battery Engine
Planetary Gear
Unit
Wheel
Wheel
ECM
Battery
ECU
Hydraulic
Brake
Actual
Regenerative
Braking Factor
Auxiliary
Battery
Mechanical Power Path
Electrical Signal Hydraulic
Converter
25

SYSTEM DIAGRAM

THS (TOYOTA HYBRID SYSTEM)
182TH22
1. READY Light
2. Output Control
Warning Light 3. Master Warning Light
4. Malfunction Indicator light 5. Discharge Warning Light
6. EMPS Malfunction
Warning Light7. HV Battery Warning Light
8. Hybrid System
Malfunction Warning
Light 32
INDICATOR AND WARNING LIGHT
The warning lights of the Prius are different from those on conventional vehicles. Inspection and repair
should be performed while referring to the troubleshooting section in the 2001 Prius repair manual
(RM778U).

Center Meter 
Multi Information Display 
1. READY lightTurns on when the ignition switch is turned to START to indicate that the ve-
hicle is ready to drive.
2. Output control
warning lightTurns on when the remaining HV battery charge becomes insufficient at R
range or when there is an abnormal temperature rise in the HV battery due
to continuous driving under heavy loads. It may also light when the HV bat-
tery temperature is low (after starting at low temperatures). The hybrid sys-
tem output is limited while this light is on.
Travel at reduced speeds (avoid sudden acceleration) while the light is lit.
3. Master warning
lightTurns on with buzzer sounding by linked operation with warning lights ª6º
to ª8º on the multi center display.
4. Malfunction
indicator lightTurns on when there is a malfunction in the engine control system.
5. Discharge warning
lightTurns on when there is a malfunction in the 12 V charging system (converter
assembly).
If it turns on together with the master warning light and hybrid system
warning light, check the diagnostic code.
6. EMPS malfunction
warning lightTurns on when there is a malfunction in the EMPS control system.
7. HV battery warning
lightTurns on when the HV battery is discharged to the lower limit.
8. Hybrid system
warning lightTurns on when a malfunction in MG1, 2, inverter, HV battery or HV ECU
is detected.

THS (TOYOTA HYBRID SYSTEM)
182TH12
SOCExample of change in SOC
Upper SOC control limit
Control regionTarget SOC
control
Lower SOC control limit
Time
Overcharged region
Overcharged region
39
1. Battery ECU
The battery ECU provides the following functions.
SOC (state of charge) Control
While the vehicle is in motion, the HV battery
undergoes repetitive charging / discharging
cycles, as it becomes discharged by the MG2
during acceleration and charged by the regenera-
tive brake during deceleration. The battery ECU
outputs charge / discharge requests to the HV
ECU so that the SOC can be constantly main-
tained at a center level, by estimating the charg-
ing / discharging amperage.
Cooling Fan Control
To ensure the HV battery's performance considering the heat that is generated in the HV battery during
charging and discharging, the battery ECU controls the operation of the cooling fan.
HV Battery Malfunction Monitoring
This function includes the monitoring of the temperature and the voltage of the battery via the battery ECU.
If a malfunction is detected, the battery ECU protects the HV battery by restricting or stopping the charging
and discharging of the HV battery. In addition, this function illuminates the warning light, outputs DTCs
(Diagnostic Trouble Codes), and stores them in memory. For further details on the DTCs, refer to the 2001
Prius Repair Manual (Pub No. RM778U).