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

Prius PHEV TechInfo

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Technical information on the PRIUS useful when designing a conversion.

Original generation

This is the original 4-door sedan:

  • 1997 Japan only release, chassis NHW10 (Gen 1)
  • 2000 worldwide release, chassis NHW11 (Sometimes also called Gen 1, sometimes Gen 2)

Present generation

This is the 5-door hatchback, sometimes called Gen 2, sometimes called Gen 3:

  • 2003 worldwide release, chassis NHW20.

Traction battery

Reconnecting traction battery

  • When working on the HV, remove the orange Service Plug on left end of the battery pack
  • After plugging the orange Service Plug back in:
    • Make sure to slide the Service Plug's handle all the way down. If you don't do this, you can't put the car in "Ready"
    • Disconnect the negative of the 12 V battery for 10 s, reconnect. If you don't do this step, the /!\ symbol will appear on the dashboard, and the car with an explamation point will appear in the Multi-Function Display:
    • Calibrate the "Auto" function of the driver's window. If you don't do this, you can't open or close the window all the way with the Auto switch.
      • Open window half-way
      • Pull and hold window switch up until window is all the way up, and hold an additional 1 second or more

Cabling to traction battery

Harness to the battery

The harness to the traction battery has 3 tails, each with a connector

  • To Battery ECU - power, communication, fan control
  • To the orange Service Plug - to detect if the Service Plug is fully plugged-in
  • To the System Relays - to drive the relays that connect the traction battery to the inverter

Pin-out of connector on Battery ECU

Battery ECU (electronic Control Unit)

    • Gnd - to chassis
    • AM - 12 V, always on, for memory retention
    • IGCT - 12 V when the car is in the "READY" mode
    • IG - 12 V when ignition is on
    • CANH - CAN bus High
    • CANL - CAN bus Low
    • VM - monitors fan voltage, 2 to 12 V
    • SI - variable duty cycle (PWM) square wave to control fan speed
    • FCTL1 - drives the relay which in turn powers the fan

Service Plug sensor.
Two pins. Shorted when the Service Plug is fully plugged-in

System Relays
Four pins:

  • Common
  • System relay 1 (precharge resistor)
  • System relay 2 (traction pack +, bypassing precharge resistor)
  • System relay 3 (traction pack -)

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