1. Overall Main Components [Electric Power Path] : AC : DC
Manager
Overall
Main Components
[Electric Power Path]
: AC
: DC
Hybrid Vehicle Transaxle Assembly
Engine
Power Split Planetary Gear Unit
MG1
HV Battery
MG2
Motor Speed Reduction Planetary Gear Unit
Inverter with Converter Assembly
New Model Prius 2009

2. Overall Gear Train 2 planetary gear units MG2 MG1 Engine Counter Gear
Manager
Overall
Gear Train
2 planetary gear units
MG1
MG2
Engine
To Front Wheel
Counter Gear
Engine: Planetary Carrier (Power Split Planetary Gear Unit)
MG1: Sun Gear (Power Split Planetary Gear Unit)
MG2: Sun Gear (Motor Speed Reduction Planetary Gear Unit)
New Model Prius 2009

3. Overall Major Difference from previous model Item Contents MG1 / MG2
Manager
Overall
Major Difference from previous model
Item
Contents
MG1 / MG2
Weight reduction
Max. output is increased
Max. system voltage is increased
Inverter
Volume reduction
Boost voltage is increased (Max. 650 V)
Maintenance interval of SLLC is changed
A/C inverter is separated
HV Control
Various driving mode is adopted - EV drive mode - ECO drive mode - PWR mode
New Model Prius 2009

4. Components Layout of Main Components 2ZR-FXE Engine HV Battery Unit
Manager
Components
Layout of Main Components
HV Battery Unit
Battery Module (DC V)
Junction Block
Battery Smart Unit
Auxiliary Battery
(Sealed Type)
2ZR-FXE Engine
Cooler Compressor with Motor Assembly
Power Cable
Insulation and Isolation of High-voltage
Both positive and negative terminals of every high-voltage circuit are insulated from body ground.
An orange colored cover is used for all high-voltage cables so that customers and technicians can easily distinguish high-voltage cables.
A case or cover is provided for each of the high-voltage units (HV battery, Inverter with Converter Assembly, Hybrid Transaxle, etc.) and high-voltage cables.
Power Management Control ECU (HV CPU)
ECM
Inverter with Converter Assembly
Boost Converter • Inverter
MG ECU
DC/DC Converter for Auxiliary Battery
P410 Hybrid Transaxle
MG1 • MG2
New Model Prius 2009

5. MG (Motor Generator) MG1 and MG2 Features
Manager
MG (Motor Generator)
MG1 and MG2
Features
Total weight is reduced (Approx. 33%) and Max. motor output (MG2) is increased (from 50 kW to 60 kW)
MG1
MG2
Previous Model
New PRIUS
More compact, more light weight design achieved through centralized winding of the coils.
Motor rotational speed was significantly increased, improving power performance
New Model Prius 2009

6. Permanent Magnet Motor
Manager
MG (Motor Generator)
MG1 and MG2
Specifications
New PRIUS
Previous Model
MG1
Type
Permanent Magnet Motor 
Max. System Voltage
AC 650 V
AC 500 V
MG2
Max. Output
60 kW (80 HP)
50 kW (67 HP)
Max. Torque
207 Nm (153 ftlbf)
400 Nm (295 ftlbf) *
546 Nm (403 ftlbf)
Cooling System
Water-cooled
Air-cooled
MG (Motor Generator)
*: Torque is boosted 2.64 times by the motor speed reduction planetary gear unit.
New Model Prius 2009

7. Inverter with Converter Assembly
Manager
Inverter with Converter Assembly
Cooling System
Inverter assembly is cooled by the dedicated radiator of a cooling system that is separate from that of the engine cooling system
Inverter with Converter Assembly
HV Radiator Reserve Tank
HV Radiator (for Inverter)
Inverter with Converter Assembly
HV Radiator Reserve Tank
This cooling system (HV water pump with motor) always activates when the power mode is selected to READY-ON state.
Radiator for inverter is located above A/C condenser
HV Water Pump with Motor
HV Radiator
HV Transaxle
HV Water Pump with Motor
New Model Prius 2009

8. Inverter with Converter Assembly
Manager
Inverter with Converter Assembly
Cooling System
Maintenance interval of coolant is slightly changed
New PRIUS
Previous Model
Coolant Type
TOYOTA Genuine Super Long Life Coolant (SLLC) or Equivalent 
Capacity
3.4 liters
(3.6 US qts, 3.0 Imp. qts) —
Maintenance Interval
Inspect
Same as previous model
Differ among the destination
Replace
First Time km km
Subsequent
New Model Prius 2009

9. HV Control System Various Driving Mode
Manager
HV Control System
Various Driving Mode
New PRIUS has a various driving mode.
EV Drive Mode Indicator Light
Driving with only the electric motor
ECO MODE Indicator Light (New Item)
Moderates the response of the accelerator pedal operation to support ECO driving
EV Drive Mode Indicator Light (Basic operation is the same as the previous model (except –A model). - EV drive mode indicator light informs the driver that the EV drive mode is entered. - In the EV drive mode, the vehicle runs like an electric vehicle which is driven with only the electric motor.
ECO MODE Indicator Light (New Items) - ECO MODE indicator light informs the driver that the ECO drive mode is entered. - This mode moderates the response of the accelerator pedal operation to support ECO driving.
PWR MODE Indicator Light - PWR MODE indicator light informs the driver that the power mode is entered. - This system optimizes acceleration performance by increasing the motive force in the acceleration pedal opening middle range more than normal.
Eco Driving Indicator Light (Basic operation is the conventional vehicle) - Eco driving indicator light informs the driver of whether the accelerator pedal is being operated in an environmental friendly manner by illumination.
PWR MODE Indicator Light
Optimizes acceleration performance by increasing the motive force in the acceleration pedal opening
New Model Prius 2009

10. High-voltage Cable for HV Battery
Manager
HV Control System
Cutoff of High-voltage Circuits
Interlock switch (connector)
Inverter with converter assembly portion
HV battery portion
High-voltage Cable for HV Battery
Connector
Connector
Connector
Service Plug
New Model Prius 2009

11. Service Point (Inverter with Converter Assembly)
Manager
Service Point (Inverter with Converter Assembly)
Hybrid Coolant Replacement
Draining method
Drain plug for hybrid system coolant
Filler Plug for Hybrid Transaxle Fluid (10 mm Hexagon)
Front
Measure the volume of the drained coolant, and replace it with a volume that is greater than the drained coolant (as a guide for bleeding air).
Drain Plug for Hybrid Transaxle Fluid (10 mm Hexagon)
Drain Plug for Hybrid System Coolant (10 mm Hexagon)
New Model Prius 2009