Toyota Prius Hybrid Repair and Maintenance Manual 2004, 2005, 2006, 2007, 2008

• 2004-2008 Prius NHW20
• 1NZ-FXE Engine

The Toyota Hybrid System (THS) is a powertrain management system that controls the operation of the gasoline engine, two high voltage electric motor/generators, a high voltage battery, the hybrid transaxle, and all related systems.

The 2001-2003 model Prius was the first Toyota hybrid model to be sold in North America with the Toyota Hybrid System. THS was an innovative, clean-sheet-of-paper design that provided a significant increase in vehicle operating economy and reduced emissions.

This chapter includes a detailed look at many of the innovative and unique features of THS II on the 2004-2008 Prius.

The gasoline engine used in the Prius is an in-line 1.5 liter 4-cylinder engine. The Toyota engine code is 1NZ-FXE. This is a modern dual overhead camshaft 16-valve engine that has been modified to work efficiently with the hybrid system. As used in this vehicle, the engine performs two functions:

• Provides power to drive the front wheels (along with motor/generator 2 (MG2).



• Turns motor/generator 1 (MG1) as a generator to recharge the high voltage battery.

The Prius engine has low-tension piston rings, light valve springs, and a low maximum rpm to help reduce friction and optimize midrange torque and economy. The engine also has several modifications and features expressly developed to optimize engine operation with the hybrid system.

DOOR WINDOW GLASS | REMOVING AND INSTALLING

Left front door window removal is described in this procedure. Other door assemblies are similar.

• Switch hybrid system OFF (READY indicator not illuminated). See 3 Safety.


WARNING! Make sure hybrid system is OFF when servicing vehicle (READY indicator not illuminated). Failure to switch the hybrid system OFF could result in engine start at any time.


• Remove door switch assembly. See 10 Electrical System, Lights.



• Remove inner door panel. See Door Panel, removing and installing in this chapter.

WORKING AT INSIDE DOOR RELEASE HANDLE:
(See photo)

• Use plastic prying tool to pull off clip.



• Slide handle rearward and tilt out of door (see curved arrow).



• Disengage door lock release cables from plastic clip on door (see arrow).



• Remove outside rear view mirror. See Outside rear-view mirror, removing and installing in this chapter.

• Foreword
• Vehicle Identification, VIN Decoder
• Familiarization
• Prius Hybrid System
• Safety
• Service and Repair Fundamentals
• Engine
• Emission Controls
• Hybrid Transaxle
• Brakes, Suspension and Steering
• Body
• Electrical System, Lights
• Diagnostics
• Electrical Component Locations
• Electrical Wiring Diagrams
• Toyota Pocket Reference Guide
• Toyota Emergency Response Guide