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Toyota Prius ZVW41 Series, Dismantling Manual

The Toyota Prius ZVW41 Series Dismantling Manual is a comprehensive and essential guide for those in need of instructions on safely disassembling their vehicle. This manual can be easily downloaded for free from our website, ensuring you have the necessary information to dismantle your Prius with confidence.

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Table of Contents 

 

About the Prius V ......................................................................................................................................1

 

Prius V Identification ................................................................................................................................2

 

Exterior .........................................................................................................................................................3

 

Prius V Identification (Continued)...........................................................................................................4

 

Interior...........................................................................................................................................................4

 

Engine Compartment ....................................................................................................................................5

 

Hybrid Component Locations & Descriptions........................................................................................6

 

Specifications ................................................................................................................................................7

 

Hybrid Synergy Drive Operation.............................................................................................................8

 

Vehicle Operation..........................................................................................................................................8

 

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery.....................................................................9

 

HV Battery Pack............................................................................................................................................9

 

Components Powered by the HV Battery Pack.............................................................................................9

 

HV Battery Pack Recycling ......................................................................................................................... 10

 

Auxiliary Battery .......................................................................................................................................... 10

 

High Voltage Safety ................................................................................................................................. 11

 

High Voltage Safety System........................................................................................................................ 11

 

Service Plug Grip ........................................................................................................................................ 12

 

Precaution to be observed when dismantling the vehicle .....................................................................13

 

Necessary Items ......................................................................................................................................... 13

 

Spills..........................................................................................................................................................14

 

Dismantling the vehicle ...........................................................................................................................15

 

Removal of HV battery ...........................................................................................................................18

 

HV Battery Caution Label ........................................................................................................................... 26

 

 

 

 

Summary of Contents for Prius ZVW41 Series

Page 1: ...Gasoline Electric Hybrid Synergy Drive ZVW41 Series ...

Page 2: ... Vehicle HV battery pack is kept safe and secure in an accident The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in some battery operated power tools and other consumer products The electrolyte is absorbed in the cell plates and will not normally leak out even if the battery is cracked In the unlikely event the electrolyte does leak it can be easil...

Page 3: ...ion 8 Vehicle Operation 8 Hybrid Vehicle HV Battery Pack and Auxiliary Battery 9 HV Battery Pack 9 Components Powered by the HV Battery Pack 9 HV Battery Pack Recycling 10 Auxiliary Battery 10 High Voltage Safety 11 High Voltage Safety System 11 Service Plug Grip 12 Precaution to be observed when dismantling the vehicle 13 Necessary Items 13 Spills 14 Dismantling the vehicle 15 Removal of HV batte...

Page 4: ......

Page 5: ...the vehicle The following illustration demonstrates how the Prius V operates in various driving modes n During light acceleration at low speeds the vehicle is powered by the electric motor The gasoline engine is shut off o During normal driving the vehicle is powered mainly by the gasoline engine The gasoline engine also powers the generator to recharge the battery pack p During full acceleration ...

Page 6: ...ed to assist in identification The alphanumeric 17 character Vehicle Identification Number VIN is provided in the front windshield cowl right side floor and on the left side B pillar Example VIN JTDZN3EU0C3000101 A Prius V is identified by the first 8 alphanumeric characters JTDZN3EU Left Side Windshield Right Side Floor and Left Side Door Pillar 2 ...

Page 7: ...us V Identification Continued Exterior and logos on the back door n o logo on each front fender Exterior Left Side View Exterior Front View Exterior Rear View Exterior Rear and Left Side View o n n o n n 3 ...

Page 8: ...ndicators warning lights located in center of the dash and near the base of the windshield Hint If the vehicle is shut off the instrument cluster gauges will be blacked out not illuminated Interior View of Front Door Sill Scuff Plate Instrument Cluster View p p READY Indicator Shift State Indicator 4 ...

Page 9: ...Identification Continued Engine Compartment q 1 8 liter aluminum alloy gasoline engine r Logo on the plastic engine cover s Orange colored high voltage power cables Engine Compartment View Power Cables r q s 5 ...

Page 10: ... the electric motors The inverter converter also converts AC electricity from the electric generator and electric motors regenerative braking to DC that recharges the HV battery pack Gasoline r Engine Engine Compartment Provides two functions 1 Powers vehicle 2 Powers generator to recharge the HV battery pack The engine is started and stopped under control of the vehicle computer Electrics Motor E...

Page 11: ...t Motor Transmission Automatic Only electrically controlled continuously variable transaxle HV Battery 201 6 Volt Sealed NiMH Battery Curb Weight 3 295 lbs 1 495 kg Fuel Tank 11 9 gals 45 0 liters Frame Material Steel Unibody Body Material Steel Panels except for Aluminum Hood and Optional Polycarbonate Roof Seating Capacity 5 standard n r o p q ts n u r p o t s q v 7 ...

Page 12: ...cle is on and operational even though the gasoline engine may be off and the engine compartment is silent Vehicle Operation With the Prius V the gasoline engine may stop and start at any time while the READY indicator is on Never assume that the vehicle is shut off just because the engine is off Always look for the READY indicator status The vehicle is shut off when the READY indicator is off The ...

Page 13: ...led case The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and sodium hydroxide The electrolyte is absorbed into the battery cell plates and will not normally leak even in a collision In the unlikely event that the battery pack is overcharged the modules vent gases directly outside the vehicle through a vent hose HV Battery Pack Battery pack voltage 201 6 V Number...

Page 14: ...acid 12 Volt battery This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle As with other conventional vehicles the auxiliary battery is grounded to the metal chassis of the vehicle The auxiliary battery is located in the cargo area It is concealed by the deck board and auxiliary box on the right side in the rear quarter panel well 201 6 Volt HV Batte...

Page 15: ...are controlled by 12 Volt normally open relays p When the vehicle is shut off the relays stop electricity flow from leaving the HV battery pack WARNING The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled To prevent serious injury or death from severe burns or electric shock avoid touching cutting or opening any orange high voltage power cable o...

Page 16: ...Safety System Vehicle On and Operational READY ON o q n o p p o HV Battery Pack Inverter Converter Hybrid Vehicle Computer Volts DC Volts DC A C 12 Volts Auxiliary Battery 12 Volts Auxiliary Battery HV Battery Pack Volts DC Hybrid Vehicle Computer Inverter Converter AC 3 Phase Electric Motor Electric Generator Compressor Volts DC A C Compressor Electric Generator AC 3 Phase Electric Motor 12 ...

Page 17: ...ge high voltage power cable or high voltage component Necessary Items Protective clothing such as insulated gloves electrically insulated rubber gloves safety goggles and safety shoes Insulating tape such as electrical tape that has a suitable electrical insulation rating Before wearing insulated gloves make sure that they are not cracked ruptured torn or damaged in any way Do not wear wet insulat...

Page 18: ...ubstance is approximately in the middle of this scale Adding a weak acidic mixture such as a dilute boric acid solution or vinegar to the caustic alkaline electrolyte will cause the electrolyte to be neutralized This is similar but opposite to the use of baking soda to neutralize a lead acid battery electrolyte spill A Toyota Material Safety Data Sheets MSDS is attached to this document Handle NiM...

Page 19: ...ting or opening any orange high voltage power cable or any high voltage component 1 Shut off the ignition READY indicator is off Then disconnect the cable from the auxiliary battery negative terminal 1 Remove the 3 deck boards 2 Remove the auxiliary boxes 3 Disconnect the battery negative terminal 2 Remove the service plug grip Caution Wear insulated gloves for the following 3 steps 1 Slide the ha...

Page 20: ...ing or touching a bare high voltage terminal wear insulated gloves 7 Check the HV battery and nearby area for leakage If you find any liquid it may be strong alkaline electrolyte Wear rubber gloves and goggles and neutralize the liquid using a saturated boric acid solution or vinegar Then wipe up the liquid using waste rags etc 8 If the electrolyte comes into contact with your skin wash the skin i...

Page 21: ...17 ...

Page 22: ...rcuit has a condenser that stores power Make sure that the tester reading is 0 V before touching any high voltage terminals which are not insulated The SRS may remain powered for up to 90 seconds after the vehicle is shut off or disabled To prevent serious injury or death from unintentional SRS deployment avoid cutting the SRS components 1 SHUT OFF IGINITION READY indicator is off 2 REMOVE TONNEAU...

Page 23: ...ry battery 4 REMOVE SERVICE PLUG GRIP Caution Wear insulated gloves for the following 3 steps HV battery 1 Raise the release handle of the service plug grip as shown in the illustration below Service Plug Grip 2 Remove the service plug grip 3 Apply insulating tape to the socket of the service plug grip to insulate it 5 REMOVE 9 BOLTS AND INVERTER TERMINAL COVER 19 ...

Page 24: ... Standard voltage 0 V Hint Set the tester to DC 750 Volts measure the voltage This inspection is performed to verify that it is safe to remove the HV battery 7 REMOVE REAR NO 1 FLOOR BOARD 1 Remove the bolt 2 Disengage the 3 claws fastener and 4 guides and remove the rear No 1 floor board 8 REMOVE REAR SEAT ASSEMBLY RH 1 Lift up the seat track adjusting handle and move the seat to the rearmost pos...

Page 25: ... track bracket cover 4 Lift up the seat track adjusting handle and move the seat to the foremost position 5 Disengage the 4 claws and remove the rear inner seat track bracket cover 6 Remove the bolt and rear seat leg stopper 7 Remove the 3 bolts on the rear side of the seat 21 ...

Page 26: ...ssembly RH 9 REMOVE NO 1 HYBRID BATTERY INTAKE DUCT 1 Using a clip remover remove the clip 2 Turn over the front floor carpet 3 Remove the 2 clips and No 1 hybrid battery intake duct 10 REMOVE NO 1 HYBRID BATTERY EXHAUST DUCT 1 Remove the clip and No 1 hybrid battery exhaust duct 11 REMOVE BATTERY COOLING BLOWER ASSEMBLY 1 Disconnect the 2 wire harness clamps 22 ...

Page 27: ...TERY COVER SUB ASSEMBLY Caution Wear insulated gloves for the following 2 steps 1 Using the service plug grip remove the battery cover lock striker Hint Insert the projecting part of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock 2 Remove the 4 nuts and upper hybrid battery cover sub assembly 23 ...

Page 28: ...amp and frame wire 14 REMOVE NO 7 HYBRID VEHICLE BATTERY UPPER CARRIER BRACKET 1 Disconnect the 2 wire harness clamps 2 Remove the bolt and No 7 hybrid battery upper carrier bracket 15 REMOVE HV BATTERY Caution Wear insulated gloves Notice Since the HV battery is very heavy 2 people are needed to remove the HV battery When removing the HV battery do not damage the parts around it 1 Disconnect the ...

Page 29: ...ack is recyclable Contact your Toyota distributor if included on the HV battery caution label or contact the nearest Toyota dealer see the next 2 pages for samples of the HV battery caution label Caution After removing the HV battery do not reinstall the service plug grip to the HV battery 25 ...

Page 30: ...HV Battery Caution Label 1 For U S A 2 Fo CANADA r 26 ...

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