TOYOTA PRIUS PLUS 2012 Service Manual

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Before driving
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Charging the hybrid battery (traction battery)
As the gasoline engine charges the hybrid battery (traction battery), the
battery does not need to be charged from an outside source. However, if
the vehicle is left parked for a long time the hybrid battery (traction bat-
tery) will slowly discharge. For this reason, be sure to drive the vehicle at
least once every few months for at least 30 minutes or 16 km (10 miles).
If the hybrid battery (traction battery) becomes fully discharged and you
are unable to jump-start the vehicle with the 12-volt battery, contact any
authorized Toyota dealer or repairer, or another duly qualified and
equipped professional.
If the shift position is in N, the hybrid battery (traction battery) will not be
charged. Always shift the shift position in P when the vehicle is stopped.
When driving in heavy traffic, operate the vehicle with the shift position in
D or B to avoid discharging the hybrid battery (traction battery).
Charging the 12-volt battery
P. 525
After the 12-volt battery has discharged or has been changed or
removed
The gasoline engine may not stop even if the vehicle is running on the hybrid
battery (traction battery). If this continues for a few days, contact any autho-
rized Toyota dealer or repairer, or another duly qualified and equipped pro-
fessional.

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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) 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 the brake pedal
is depressed and accelerator is loosened.
Other sounds, such as motors and mechanical noises, may be heard
from the brake system when the brake pedal is depressed.
Vibration may be felt when the gasoline engine starts or stops.
Cooling fan sounds may be heard from the air intake vent. (
P. 44)
The operation sound of the air conditioning system (air conditioning com-
pressor, blower motor).
Maintenance, repair, recycling, and disposal
Contact any authorized Toyota dealer or repairer, or another duly qualified
and equipped professional regarding maintenance, repair, recycling and dis-
posal. Do not dispose of the vehicle yourself.

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1-1. Hybrid system
Before driving
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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.
Air conditioning compressor
High voltage cables (orange)
Power control unit and DC/
DC converter
Electric motor (traction
motor)Hybrid battery (traction bat-
tery)
Caution label
Service plug

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Hybrid battery (traction battery) air vent
There is an air intake vent under
the right-hand front seat for the
purpose of cooling the hybrid
battery (traction battery). If the
vent becomes blocked, the
hybrid battery (traction battery)
may overheat, leading to a
reduction in hybrid battery (trac-
tion battery) output.
Emergency shut off system
When a certain level of impact is detected by the impact sensor, the
emergency shut off system blocks off the high voltage current and
stops the fuel pump to minimize the risk of electrocution and fuel
leakage. If the emergency shut off system activates, your vehicle will
not restart. To restart the hybrid system, contact any authorized
Toyota dealer or repairer, or another duly qualified and equipped pro-
fessional.

45 1-1. Hybrid system
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Before driving
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If a warning light comes on, a warning 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 any authorized Toyota
dealer or repairer, or another duly qualified and equipped professional.
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. 476) 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 7 L [1.8 gal.,
1.5 Imp.gal.], when the vehicle is on a level surface. This value may vary
when the vehicle is on a slope.)
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)
The hybrid battery (traction battery) has a limited service life. The lifespan of
the hybrid battery (traction battery) can change in accordance with driving
style and driving conditions.
Declaration of conformity
This model conforms to hydrogen emissions according to regulation
ECE100 (Battery electric vehicle safety).

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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 under the console
box. The service plug is used only
when the vehicle is serviced and is sub-
ject to high voltage.

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Before driving
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CAUTION
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-temperature 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. 461)
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)
Your vehicle contains a sealed lithium-ion battery. If disposed of improperly,
it is hazardous to the environment and there is a risk of severe burns and
electrical shock that may result in death or serious injury.
NOTICE
Hybrid battery (traction battery) air vent
Do not put foreign objects near the air vent. The hybrid battery (traction
battery) may overheat and be damaged.
Clean the air vent regularly to prevent the hybrid battery (traction battery)
from overheating.
Do not wet or allow foreign substances to enter the air vent as this may
cause a short circuit and damage the hybrid battery (traction battery).
Do not carry large amounts of water such as water cooler bottles in the
vehicle. If water spills onto the hybrid battery (traction battery), the battery
may be damaged. Have the vehicle inspected by any authorized Toyota
dealer or repairer, or another duly qualified and equipped professional.

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1-1. Hybrid system
Before driving
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Energy monitor/consumption screen
Energy monitor
Displays the flow of energy as it changes in accordance with driving
conditions.
“touch screen”
Press “CAR”.
If the “Trip information” screen is
displayed, touch “Energy”.
You can view the status of your hybrid system on the “touch screen”
screen or the navigation system screen.
“touch screen” screen or navi-
gation system screen

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ConditionDisplay
When the vehicle is powered by
the electric motor (traction
motor)
When the vehicle is powered by
both the gasoline engine and the
electric motor (traction motor)
When the vehicle is powered by
the gasoline engine