Talk:PriusPlus-Electronic

These are the steps involved to convert a Toyota Prius into a PiPrius. There are a number of tasks to be completed in order for the entire system to function properly. Those tasks are covered in the following subsections of the Conversion Procedures. These instructions are currently under development and may not yet be complete.

References

You should be familiar with these reference materials and standard operating procedures around high voltages. <references/>

Installing the CAN-View Version 3 and Prius EV Mode Button both involve disassembling the same areas of the Prius so will be covered here at the same time. You should also be familiar with these ^cv#reference materials.

• ^cv1. File:Stereo Accessory Install Guide 04 Prius v1.03.pdf from http://www.chrisdragon.com
• ^cv2. File:PriusXMradio3.2.pdf from https://www.metrotpn.com
• ^cv3. File:CAN-View installNONAVwt.pdf Adapted from http://www.hybridinterfaces.ca/installNONAV.html
• ^cv4. File:CAN-View installWNAVwt.pdf Adapted from http://www.hybridinterfaces.ca/installWNAV.html
• ^cv5. File:Prius-evbutton-install.pdf from http://www.calcars.org/prius-evbutton-install.pdf
• ^cv6. File:FactoryEV.pdf from http://www.scubadivervideo.com/Files/factoryEV.pdf

We begin by disassembling the dashboard. ^{cv1 cv2}

1. Remove the bottom cover of steering column
   1. Releasing the steering wheel adjustment handle and removing the silver screw.
   2. Turn steering wheel 90 degrees to right and left to remove black screws on each side.
   3. Remove the lower cover by carefully pulling down on lower half.
2. Disconnect the headlamp flasher plug on left side of steering column.
   1. Remove plugs cover by unlocking two side tabs/clips.
   2. Remove 3 unused connector pins using a jeweler's screwdriver to disengage and slide them out.
   3. Optionally to use the headlamp flasher circuit as an EV Mode button:
      1. Solder some length?? of black wire to a new pin and use it to replace:
      2. The Red(#11-B10) wire to preserve day time flashing function, will disable night time flashing. It has been discovered that this does not work properly as the red wire is used for both the high beam and flash functions when the lights are turned on, thus disabling high beams at night. Anyone who has implemented this option should reinstall the red wire, moving the ev-mode button wire to the violet wires location instead.
      3. The Violet(#17-B4) wire to preserve night time flashing function, will disable day time flashing.
      4. Route new black wire along existing bundle then towards center console to later meet up with OBDII cable.
   4. Snap the cover back onto the flasher plug and reinsert into switch.
   5. Reassemble steering column, be sure everything is aligned properly.
3. Remove lower glove box by squeezing the inside sides together to lower box below catches, then unclip the small piston from right side. Lower box until the lower joints detach from dash, remove pneumatic cylinder noting it's orientation.
4. Remove passenger side silver air vent cover by pulling out from the bottom first. Next remove the small interior colored piece just below the vent piece by pulling straight out.
   1. If installing CAN-View Without Navigation: ^cv3
   2. Remove drivers side air vent cover, press down and pull out on top.
   3. Remove lower center console hump with 12v lighter power socket, remove barb from passenger side, pull out.
   4. Remove air vent at right side of MFD screen, open upper glove box to pull out vent.
   5. Remove lower drivers side interior colored dash panel, one black screw above hood release, one exposed behind drivers side vent.
   6. Remove black lower dash key fob panel, leave hanging with wires connected.
   7. Remove upper drivers side dash panel with power button, leave wires attached.
   8. Remove air vent at left side of MFD screen, the shift lever with remain in place, detach and slide park button forward through silver panel to expose and detach cable, then remove the panel and reattach the park button to it's cable to prevent errors during later tests.
   9. Remove 10mm bolts, one on each side of MFD screen, pull screen out sharply and rotate towards drivers side.
   10. Tap grey OEM wire for 12v power, top row 2nd from the left.
   11. Attach CAN-View video cable to MFD and power spade to tapped grey wire, run cable out directly behind screen.
   12. Connect CAN-View OBDII cable to OBDII port and route cable behind center console towards glove box along with headlamp flasher ev-mode button wire if installed.
   13. Test CAN-View, then reassemble center and drivers side of dash.
   14. CAN-View will be mounted under passenger seat, above JBL amplifier if present.
5. If installing CAN-View With Navigation: ^cv4
   1. Route OBDII Cable around foot well and down drivers side door sill to underneath drivers seat. Route headlamp flasher ev-mode button wire if installed behind center console and glove box.
   2. Tap grey OEM wire from navigation unit for 12v power.
   3. Connect CAN-View video cables to navigation unit.
   4. Test and attach above and to rear of navigation unit.
6. Solder new pin to some length?? of black wire, and optionally the black wire which connects to the headlamp flasher.
7. Install pin with black wire(s) to ev-mode button location in HV ECU H14#27. ^{cv5 cv6}
   1. The HV ECU is the one closest the exterior of the car with grey plugs.
   2. H14 is the lowest of the four connectors.
   3. Pin #27 is located on the most interior (broken into three segments) row, the second from the bottom left corner, in the only open location between two red wires.
   4. Using a jeweler's screwdriver raise the white terminal retainer, fully insert the new pin, re-compress the retainer, and plug terminal back into HV ECU.
8. Route black EV Mode wire, and OBDII & Video if non-NAV, along passenger side door trim exiting under carpet before pillar to the hole in carpet below passenger seat and to relay cable.
9. Route relay cable from CAN-View under rear passenger side door trim towards rear of car.
10. Reassemble passenger side of dash and door trim.

Finally, Connect all the cables to CAN-View.

CAN-View Configuration

1. Configure CAN-View, should be preconfigured.
   1. RL1 = EV-Mode Button trigger
   2. RL4 on if bat.temp. < +111 DegF
   3. RL4 on if CCL is > 40 ACL
   4. Battery Capacity 10.0Ah
   5. RL2 = < 69 > 70% SOC and > 70 < 70 ACL, 0s, NO
   6. RL3 = < 74 > 74% SOC and > 50 < 45 MPH, 0s, NO
   7. RL5 = Regen ?
   8. RL6 = HeartBeat ?

OEM HV Battery Modifications

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources. Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril. Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer. See also our My wiki:General disclaimer talk:Disclaimer

A number of wires are added within the OEM HV Battery box, including two HV cables which will exit the box and a short HV jumper cable through the HAL sensor. In addition one or more low voltage wires and taps may be added.

1. Remove trunk carpet, all storage compartments, and spare tire.
2. ! ! Be Sure To Remove Orange HV Service Plug ! !
3. Install HV taps to OEM NiMH battery Pack
   1. Remove rear seat bottom, pull up front edge, unhook rear edge
   2. Remove rear battery deck upholstery 2x tie down clips ?10mm?, 2x tabs
   3. Remove drivers side rear seat back 2x 14mm
   4. Remove drivers side rear seat pillow upholstery 12mm, pull up
   5. Remove drivers side trunk panel upholstery 10mm, 10mm screw, tabs
   6. Remove drivers side OEM Battery brace 7x 12mm
   7. Remove OEM Battery ECU Cover 2x 10mm, 2x 10mm nuts
      1. Optional steps Caution: This will expose you to the OEM HV Modules
      2. Remove OEM Battery Input Air Duct 2x tape, 1 sensor
      3. Remove Passenger side OEM Battery brace 7x 12mm
      4. Remove OEM Battery Lid 4x 12mm, 4x 10mm, 4x 10mm nuts, 1 tab at end
   8. Add New HV Cables, Notch Here, Trim There, etc, etc
   9. Reassemble in reverse order
4. Replace Orange HV Service Plug

See Also:

• PriusDisMan.pdf <ref>Media:Priusdisman.pdf from http://www.airlabcorp.com/Prius/priusdisman.pdf</ref>

Mount PFC Charger

Install PFC Charger in the drivers side rear wheel well.

1. Locate and drill mount points from pattern
2. Install ventilation housing and fans
3. Mount PFC Charger

Install Battery Box

General Disclaimer:   (HV) (DC) injury or death hazard,   use at your own risk,   may void warranty.

HV (High Voltage) DC (Direct Current) Warning: Traction Battery Packs, Motors, Chargers, and other HV sources could cause serious injury or death if proper precautions are not taken while working on or around such High Voltage Direct Current sources. Use this information at your own risk: There is no warranty expressed nor implied and we are not liable for any of your past, present, nor future actions. Even should you perform these modifications to the letter you could still damage any number of components in your vehicle causing it to no longer function. Even if it appears to function properly your actions may cause it to self destruct with collateral damage to surrounding properties other than your vehicle. By utilizing these ideas and instructions in an attempting to enhance national security, reduce gas consumption, vehicle "emissions", your carbon footprint, or smog, you do so at your own risk & peril. Warranty: In performing some of these modifications you may void your warranty with the vehicles manufacturer. See also our My wiki:General disclaimer talk:Disclaimer

Install the Battery Box.

1. Locate, drill, and press nut body/frame mountpoints
2. Attach Electronics Box to bottom of lower battery box frame
3. Install and fasten lower battery box frame
4. Populate box with batteries
5. Install battery regulators and interconnects
6. Install and fasten upper battery box frame

Connect Relay Box

1. Connect everything...

Drive and Enjoy

Charge, Drive, and Repeat...