With superior mileage and reduced emissions, the Prius had
captivated drivers and technicians alike with its hybrid technology. It's
one of the few vehicles on the road to attain super ultra low emission
vehicle (SULEV) status. The earth-friendly Prius is also the core of
Toyota's worldwide Eco-Project, which is based on the philosophy of
providing clean, safe and appealing products that are "environmentally
friendly." The Prius features the Toyota Hybrid System (THS), which uses
two power sources: a gasoline engine and an electric motor. While the
Prius features hybrid technology, when it comes to collision reapir, it's
not much different from any other
vehicle. |
Please Note: The Prius contains numerous high-voltage circuits
that are capable of producing over 288 volts. Careless servicing of the
hybrid system may result in electrocution and could be fatal! If a Prius
is brought in for collision repair, review the Prius Emergency Response
Guide, along with the proper Repair Manual procedures.
| Technicians at some collision repair facilities have
expressed concern about how to repair a damaged Prius. You'll need to follow
basic precautions - outlined in this article - but in general, as long as the
high-voltage electrical system is properly deactivated, repairing the body of a
Prius is much like repairing any other vehicle. Keep in mind, though, if
mechanical repairs need to be performed or if the high-voltage battery needs to
be removed, a specially trained Toyota master technician must perform the
service.
THS Operation
Here's how the Toyota Hybrid System operates: The vehicle may be powered by
its electric motor while the gasoline-powered engine is not running. In other
instances, the gasoline-powered engine can provide the force that mechanically
drives the vehicle. Or, the gasoline-powered engine can be used to generate
electricity, which powers the electric motor to drive the vehicle and/or is used
to charge the high-voltage battery pack.
Besides basic operation of the Prius, you need to be aware of some additional
features. This article provides instructions and precautions that will help you
set up a safe environment for working on the vehicle.
In the engine compartment of the Prius, the high voltage inverter
box displays the Toyota Hybrid System logo on the cover. Also note the
orange colored high voltage power cables. | High-Voltage System Identification
All high-voltage wiring is color-coded orange. “High Voltage” caution labels
also identify the high-voltage battery pack and other high-voltage components.
- Do not carelessly handle these wires and components.
Disabling the High-Voltage
System
You or a certified technician should disable the high-voltage system by
disconnecting the negative terminal of the battery prior to performing repairs
on the body. Disconnecting the auxiliary battery shuts down the high-voltage
circuit to ensure your safety. For additional protection, the service plug can
be removed.
- The technician must wear insulated rubber gloves (lineman's gloves) when
removing the service plug.
- After removing the service plug, you must wait at least 5
minutes to allow the full discharge of the high-voltage condensers
inside the inverter.
If you or a certified technician cannot remove the service plug due to damage
to the rear portion of the vehicle, remove the hybrid vehicle (HV) fuse or the
ignition control (IGCT) relay instead.
Safety Mechanism
The main relay automatically turns OFF, shutting down the high-voltage
circuits under these conditions:
- Ignition key is turned OFF.
- The 12-volt power source is cut OFF.
- The airbag sensor or the sensor in the inverter detects a frontal
collision.
- The grip is pulled up to remove the service plug.
Therefore, in most accidents, the high-voltage system is automatically
disabled immediately. In fact, in a severe frontal impact, it's disabled before
the airbags are deployed.
In essence, once the high-voltage system is disabled, repairing the body of
the Prius is just like repairing any other Toyota, but keep in mind some
additional precautions:
- Be sure to disable the high-voltage system by disconnecting the 12-volt
battery prior to welding on the body.
- If the vehicle is disabled and cannot be driven, do not push a Prius
around the shop - it must be on wheel jacks to be moved.
- If the high-voltage battery pack has been ruptured and battery acid is in
the rear trunk area or in any other part of the vehicle, use boric acid to
neutralize the spill; then test with litmus paper to ensure it's neutral
before attempting to clean it up.
Driving a Prius is somewhat different than driving a typical gasoline-powered
car. When you drive one, follow these procedures:
The Prius contains a high voltage hybrid vehicle (HV) battery pack
and a low voltage auxillary battery. Located at the base of the trunk
behind the rear seat, the HV battery pack contains non-spillable, sealed
nickel metal hydride (NiMH) battery modules. The lead-acid, 12-volt
auxillary battery is located in the trunk and is grounded to the metal
chassis of the vehicle. | Starting the Prius
- Make sure the parking brake is engaged and the shift lever is in the park
(P) position.
- Unlike conventional vehicles, the gasoline engine will only start when
the shift lever is in the P position and will not start in the neutral (N)
position.
- While pressing the brake pedal, turn the ignition switch to the START
position and release - the READY light (ready-to-drive indicator light)
flashes.
- If the outside air temperature is low, the READY light may flash longer
than usual.
- Once the system determines the vehicle is ready to be driven, the READY
light illuminates steadily and the buzzer emits a beep.
- After the gasoline engine warms up, it stops automatically, provided
that the air conditioning compressor does not need to operate and the
high-voltage battery pack is sufficiently charged.
Caution: Unlike conventional vehicles, once the Prius illuminates the
READY light, you cannot depend on the sound of the engine running to determine
if the vehicle is ready to be driven. Always refer to the READY indicator light
to check the status of the vehicle.
Starting Out
- While pressing on the brake pedal, release the parking brake and move the
shift lever to the drive (D) position (the vehicle will move forward just like
a conventional vehicle with an automatic transmission).
- Gradually release the brake and slowly depress the accelerator to start
moving.
When starting at extremely slow speeds, the gasoline engine may remain OFF to
conserve fuel while the electric motor drives the vehicle, so don't rely on the
sound of the engine to determine if the vehicle is ready to be driven. In
addition, if the gasoline engine remains OFF during initial takeoff, it will
automatically start up when the car reaches approximately 15 mph during
acceleration.
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Toyota
Prius 20
2003-2009
1.5h
ђуководство по ремонту и техническому обслуживанию
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Toyota
Prius 30
2009-
1.8h
ђуководство по ремонту и техническому обслуживанию
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