Figure 12 1 The secondgeneration Prius is larger

Figure 12. 2 The major components of a second-generation Prius. Hybrid and Alternative Fuel

Figure 12. 3 Dash readouts of 2001– 2003 Prius. Note “Turtle” at top right.

Figure 12. 4 The energy monitor screen indicates where the mechanical and electrical energy

Figure 12. 5 The consumption screen gives feedback to the driver as to how

Figure 12. 6 A Toyota smart key. Hybrid and Alternative Fuel Vehicles James D.

Figure 12. 7 All Toyota hybrid vehicles have a “B”shifter position, as seen on

Figure 12. 8 To engage Park on a second-generation Prius, stop the vehicle and

Figure 12. 9 The second-generation Prius uses an electronic sensor to replace the conventional

Figure 12. 10 The light on the POWER button is off when the vehicle

Figure 12. 11 When the bypass valve is closed, the exhaust gases are forced

Figure 12. 12 The Prius stores its fuel in a resin bladder located inside

Figure 12. 13 The first-generation Prius battery pack with 38 modules. All of the

Figure 12. 14 The electronic controls used in a Toyota hybrid vehicle. Notice the

Figure 12. 15 High-voltage battery pack cooling on a second generation Prius. (Courtesy of

Figure 12. 16 The THS power train as used in the first-generation Prius. The

Figure 12. 17 The Toyota Hybrid System operation. Hybrid and Alternative Fuel Vehicles James

Figure 12. 18 Power train schematic for the 4 WD versions of the Highlander

Figure 12. 19 The inverter assembly from a first generation Prius. The inverter performs

Figure 12. 20 Air vent at the front edge of the rear seat in

Figure 12. 21 The boost converter is used to increase HV battery voltage to

Figure 12. 22 The rear-mounted electric motor (MGR) is used on four-wheel-drive versions of

Figure 12. 23 The EPS unit on a Toyota Highlander hybrid is powered by

Figure 12. 24 The Toyota Camry hybrid-electric vehicle does not look any different from

Figure 12. 25 The Camry Hybrid battery pack as viewed from the passenger compartment.

Figure 12. 26 The 2007 Camry Hybrid inverter assembly is more compact than those

Figure 12. 27 The high-voltage (HV) service plug being removed on a second-generation Prius.

Figure 12. 28 Verify that the system has been de-energized using a DMM before

Figure 12. 29 Removing the service plug on a Toyota Highlander Hybrid. This service

Figure 12. 30 The Toyota computer system monitors the voltage on the chassis and

Figure 12. 31 An insulation tester is used to detect any electrical connection between

Figure 12. 32 While some aftermarket scan tools will give some hybrid data, it

Figure 12. 33 The high-voltage disconnect plug on a second generation Prius (2004+) includes

Figure 12. 34 Note that Toyota’s Super Long Life Coolant is prediluted. Hybrid and

Slides: 34

Download presentation

Figure 12. 1 The second-generation Prius is larger than the first generation. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 2 The major components of a second-generation Prius. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 3 Dash readouts of 2001– 2003 Prius. Note “Turtle” at top right. An outline of a turtle will illuminate on the right-hand side of the display when the Ni. MH battery pack does not have a sufficient charge to provide additional torque. There is nothing wrong with the vehicle; it just needs to be driven less aggressively so that the generator can keep up with the Ni. MH battery pack depletion. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 4 The energy monitor screen indicates where the mechanical and electrical energy is flowing during vehicle operation. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 5 The consumption screen gives feedback to the driver as to how well his or her driving style is conserving fuel. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 6 A Toyota smart key. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 7 All Toyota hybrid vehicles have a “B”shifter position, as seen on the Camry hybrid. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 8 To engage Park on a second-generation Prius, stop the vehicle and press the “P”button. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 9 The second-generation Prius uses an electronic sensor to replace the conventional gear shift selector. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 10 The light on the POWER button is off when the vehicle is in READY mode. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 11 When the bypass valve is closed, the exhaust gases are forced through the HC adsorber, which stores unburned hydrocarbons until the TWC is up to temperature. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 12 The Prius stores its fuel in a resin bladder located inside a steel tank. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 13 The first-generation Prius battery pack with 38 modules. All of the battery cells are connected in series to create the HV battery. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 14 The electronic controls used in a Toyota hybrid vehicle. Notice the system main relays (SMR), battery ECU, and the interconnection of the various components and systems. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 15 High-voltage battery pack cooling on a second generation Prius. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 16 The THS power train as used in the first-generation Prius. The orange cables connect to the two motorgenerators located in the transmission case. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 17 The Toyota Hybrid System operation. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 18 Power train schematic for the 4 WD versions of the Highlander Hybrid and RX 400 h. Note that MGR alone is used to drive the vehicle’s rear wheels. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 19 The inverter assembly from a first generation Prius. The inverter performs multiple functions in the THS system. (Courtesy of University of Toyota and Toyota Motor Sales, U. S. A. , Inc. ) Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 20 Air vent at the front edge of the rear seat in a Lexus RX 400 h. This vent has to be kept clear to ensure proper battery operation. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 21 The boost converter is used to increase HV battery voltage to as high as 650 volts for use by the electric motors. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 22 The rear-mounted electric motor (MGR) is used on four-wheel-drive versions of the Lexus RX 400 h and Toyota Highlander. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 23 The EPS unit on a Toyota Highlander hybrid is powered by 42 volts supplied by a separate DC-DC converter. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 24 The Toyota Camry hybrid-electric vehicle does not look any different from a regular Camry except for the emblem on the side and rear of the vehicle. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 25 The Camry Hybrid battery pack as viewed from the passenger compartment. Note the cooling fan assembly on top of the battery case. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 26 The 2007 Camry Hybrid inverter assembly is more compact than those found in previous Toyota HEVs. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 27 The high-voltage (HV) service plug being removed on a second-generation Prius. The handle must be lifted straight up before rotating to the left for removal. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 28 Verify that the system has been de-energized using a DMM before touching any part of the high-voltage system. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 29 Removing the service plug on a Toyota Highlander Hybrid. This service plug is located behind a plastic panel on the left side of the rear passenger seat. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 30 The Toyota computer system monitors the voltage on the chassis and stands by ready to disable the high -voltage system if a connection to ground is detected. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 31 An insulation tester is used to detect any electrical connection between the high-voltage wiring and the chassis of the vehicle. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 32 While some aftermarket scan tools will give some hybrid data, it is wise to use the factory tool and service information. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 33 The high-voltage disconnect plug on a second generation Prius (2004+) includes a 125 -ampere fuse. Always wear protective 1, 000+ volt linesman’s gloves with protective leather gloves over them when disconnecting this plug. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.

Figure 12. 34 Note that Toyota’s Super Long Life Coolant is prediluted. Hybrid and Alternative Fuel Vehicles James D. Halderman and Tony Martin Copyright © 2009 by Pearson Education, Inc. Upper Saddle River, New Jersey 07458 All rights reserved.