TOYOTA PRIUS PHV 2013 Service Manual

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1-1. Plug-in hybrid system
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Before driving
PRIUS PHV_OM_OM47787U_(U)
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When continually using EV mode only
After driving for approximately 124 miles (200 km) with the gasoline engine
off, the gasoline engine may start for a short amount of time in order to pro-
tect the system.
■ Conditions in which the gasoline engine may not stop
The gasoline engine starts and stops automatically. However, it may not stop
automatically in the following conditions
*:
● During gasoline engine warm-up
● When the temperature of the hybrid battery (traction battery) is high or
low
● During hybrid battery (traction battery) charging
● When the heater is switched on
*: Depending on the circumstances, the gasoline engine may also not stop
automatically in situations other than those above.
■ If the vehicle is not used for a long time
The 12-volt battery may discharge. In this event, charge the 12-volt battery.
(P. 594)
In order to prevent the hybrid battery (traction battery) from becoming
extremely low in charge, start the hybrid system at least once every 2 or 3
months, and turn the “POWER” switch off after the gasoline engine has
stopped automatically. (If the gasoline engine does not start up even after
approximately 10 seconds have passed since the “READY” indicator came
on, the “POWER” switch can be turned to OFF without any further action.)

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■Sounds and vibrations specific to a hybrid vehicle
There may be no engine sounds or vibration even though the vehicle is able
to move. For safety, apply the parking brake and make sure to shift the shift
position to P when parked.
The following sounds or vibrations may occur when the hybrid system is
operating, and are not a malfunction.
● The brake system operation sound heard from the front of the vehicle
when the driver’s door is opened.
● Motor sounds may be heard from the engine compartment.
● Sounds may be heard from the hybrid battery (traction battery) behind
the rear seat when the hybrid system starts or stops.
● Sounds may be heard from the transmission when the gasoline engine
starts or stops, when driving at low speeds, or during idling.
● Engine sounds may be heard when accelerating sharply.
● Sounds may be heard due to regenerative braking when you press the
brake pedal or release the accelerator pedal.
● Vibration may be felt when the gasoline engine starts or stops.
● Cooling fan sounds may be heard from the air intake vent. ( P. 45)
● The operation sound of the air conditioning system (air conditioning com-
pressor, blower motor).

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1-1. Plug-in hybrid system
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Vehicle proximity notification system
In the following cases, the vehicle proximity notification system may be diffi-
cult for surrounding people to hear.
● In very noisy areas
● In the wind or the rain
Also, as the vehicle proximity notification system is installed on the front of
the vehicle, it may be more difficult to hear from the rear of the vehicle com-
pared to the front.
■ Maintenance, repair, recycling, and disposal
Contact your Toyota dealer regarding maintenance, repair, recycling and dis-
posal. Do not dispose of the vehicle yourself.

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1-1. Plug-in hybrid system
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Plug-in hybrid system precautions
Take care when handling the hybrid system, as it contains a high
voltage system (about 650V at maximum) as well as parts that
become extremely hot when the hybrid system is operating. Obey
the caution labels attached to the vehicle.
Service plug
Caution label
Power control unit and DC/
DC converter
Electric motor (traction
motor)Air conditioning compressor
High voltage cables (orange)
Battery charger
Hybrid battery (traction bat-
tery)
Charging inlet

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Hybrid battery (traction battery) air vents
There are air intake vents on the
side of the rear right seatback
and on the front corner of the left
rear seat cushion for the purpose
of cooling the hybrid battery
(traction battery). If the vents
become blocked, the hybrid bat-
tery (traction battery) may over-
heat, leading to a reduction in
hybrid battery (traction battery)
output.
Emergency shut off system When a certain level of impact is detected by the impact sensor, the
emergency shut off syst em blocks off the high voltage current and
stops the fuel pump to minimize t he risk of electrocution and fuel
leakage. If the emergency shut off sy stem activates, your vehicle will
not restart. To restart the hybrid system, contact your Toyota dealer.

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Hybrid warning messageA message is automatically displayed when a malfunction occurs in
the hybrid system or an impr oper operation is attempted.
If a warning message is shown
on the multi-information display,
read the message and follow the
instructions. ( P. 546)
■If a warning light comes on, a warn ing message is displayed or the 12-
volt battery is disconnected
The hybrid system may not start. In that case, try to start the system again. If
the “READY” indicator does not come on, contact your Toyota dealer.
■ Running out of fuel
When the vehicle has run out of fuel and the hybrid system cannot be
started, refuel the vehicle with at least enough gasoline to make the low fuel
level warning light ( P. 537) go off. If there is only a small amount of fuel,
the hybrid system may not be able to start. (The minimum amount of fuel to
add to make the low fuel level warning light go out is about 1.9 gal. [7.1 L,
1.6 Imp.gal.], when the vehicle is on a level surface. This value may vary
when the vehicle is on a slope.)

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Electromagnetic waves
● High voltage parts and cables on the hybrid vehicles incorporate electro-
magnetic shielding, and therefore emit approximately the same amount
of electromagnetic waves as conventional gasoline powered vehicles or
home electronic appliances.
● Your vehicle may cause sound interference in some third party-produced
radio parts.
■ Hybrid battery (traction battery) (lithium-ion battery)
The hybrid battery (traction battery) has a limited service life.
The hybrid battery (traction battery) capacity (the ability to hold a charge)
reduces with time and use in the same way as other rechargeable batteries.
The extent at which capacity reduces changes drastically depending on the
environment (ambient temperature, etc.) and usage conditions, such as \
how
the vehicle is driven and how the hybrid battery (traction battery) is charged.
This is a natural characteristic of lithium-ion batteries, and is not a malfunc-
tion. Also, even though the EV driving range decreases when the hybrid bat-
tery (traction battery) capacity reduces, vehicle performance does not
significantly become worse.
In order to reduce the possibility of the capacity reducing, follow the direc-
tions listed on P. 93, “Capacity reduction of the hybrid battery (traction bat-
tery)”.

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CAUTION
■High voltage precautions
The vehicle has high voltage DC and AC systems as well as a 12-volt sys-
tem. DC and AC high voltage is very dangerous and can cause severe burns
and electric shock that may result in death or serious injury.
● Never touch, disassemble, remove or replace the high voltage parts,
cables or their connectors.
● The hybrid system will become hot after starting as the system uses high
voltage. Be careful of both the high voltage and the high temperature, and
always obey the caution labels attached to the vehicle.
●Never try to open the service plug
access hole located in the luggage
compartment. The service plug is used
only when the vehicle is serviced and is
subject to high voltage.

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CAUTION
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Road accident cautions
If your vehicle is involved in an accident, observe the following precautions
to reduce the risk of death or serious injury:
● Stop the vehicle in a safe place to prevent subsequent accidents.
While depressing the brake pedal, apply the parking brake, shift the shift
position to P and turn the hybrid system off. Then, slowly release the brake
pedal.
● Do not touch the high voltage parts, cables and connectors.
● If electric wires are exposed inside or outside your vehicle, an electric
shock may occur. Never touch exposed electric wires.
● Do not touch the battery if liquid is leaking from or adhering to it.
If electrolyte (carbonic-based organic electrolyte) from the hybrid battery
(traction battery) comes into contact with the eyes or skin, it could cause
blindness or skin wounds. In the unlikely event that it comes into contact
with the eyes or skin, wash it off immediately with a large amount of water,
and seek immediate medical attention.
● If electrolyte is leaking from the hybrid battery (traction battery), do not
approach the vehicle.
Even in the unlikely event that the hybrid battery (traction battery) is dam-
aged, the internal construction of the battery will prevent a large amount of
electrolyte from leaking out. However, any electrolyte that does leak out
will give off an acidic vapor. This vapor is an irritant to skin and eyes and
could cause acute poisoning if inhaled.
● Do not bring burning or high-temperat ure items close to the electrolyte.
The electrolyte may ignite and cause a fire.
● If a fire occurs in the hybrid vehicle, leave the vehicle as soon as possible.
Never use a fire extinguisher that is not meant for electric fires. Using even
a small amount of water may be dangerous.

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CAUTION
●If your vehicle needs to be towed, do so with front wheels raised. If the
wheels connected to the electric motor (traction motor) are on the ground
when towing, the motor may continue to generate electricity. This may
cause a fire. ( P. 525)
● Carefully inspect the ground under the vehicle. If you find that liquid has
leaked onto the ground, the fuel system may have been damaged. Leave
the vehicle as soon as possible.
■ Hybrid battery (traction battery) (lit hium-ion battery) replacement and
disposal
Do not replace, dispose of, modify, or reuse the hybrid battery (traction bat-
tery) and do not use it for anything other than its intended use. Contact your
Toyota dealer for replacement or disposal.
If the hybrid battery (traction battery) is replaced, disposed of, modify or
reused in an improper way, or if the hybrid battery (traction battery) is used in
a way it is not intended for, there is a risk of severe burns and electrical
shock that may result in death or serious injury.
Also, improper handling of the hybrid battery (traction battery) can lead to
environmental hazards.