Engine Control System (Service Information) (Plug-In): Diagnosis Toyota Prius Plug-in

ON-VEHICLE INSPECTION

1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Connect the Techstream to the DLC3. Turn the Techstream on. Set the vehicle to the inspection mode. Refer to «INSPECTION MODE PROCEDURE»(ref-553290-S22500871302013051700000) . Start the engine. Inspect the oil control valve. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT System (Bank 1). Check the engine speed when the oil control valve is operated using the Techstream with the engine coolant temperature at 50°C (122°F) or less. HINT: When performing the Active Test, the air conditioning should be on. Engine coolant temperature when the engine is started should be 30°C (86°F) or less. Standard Control Range Specified Condition OFF Normal engine speed ON Rough idle or engine stalls (soon after oil control valve switched from OFF to ON)

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1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-553433-S31264435182013051700000)
2. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Disconnect the camshaft timing oil control valve assembly connector. Remove the bolt and remove the camshaft timing oil control valve assembly. Remove the O-ring from the camshaft timing oil control valve assembly.

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1. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 6.9 to 7.9 ohms If the result is not as specified, replace the oil control valve assembly. Check the operation. Connect a positive (+) auxiliary battery lead to terminal 1 and a negative (-) lead to terminal 2, and check the movement of the valve. TEXT IN ILLUSTRATION *1 When Applied *2 When Cut Off NOTE: Confirm that the valve moves freely and does not stick in any position. If necessary, replace the camshaft timing oil control valve assembly. HINT: Accumulation of foreign matter can cause minor pressure leaks. Minor pressure leaks will cause the camshaft to advance or retard, and this will cause a DTC to be set.

1. INSPECT THROTTLE BODY ASSEMBLY Check for throttle control motor operating sound. Turn the power switch on (IG). When depressing the accelerator pedal, check the operating sound of the motor. Make sure that no friction noises are emitted from the motor. If any friction noise exists, replace the throttle body assembly. Set the vehicle to the inspection mode. Refer to «INSPECTION MODE PROCEDURE»(ref-553290-S22500871302013051700000) . Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range when the A/C is switched off. Standard Condition Engine Idle Speed A/C switched off 950 to 1050 rpm NOTE: Be sure to perform this step with all accessories off. Make sure that park (P) is selected.

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1. DRAIN COOLANT (for Engine) . Refer to «REPLACEMENT - Step 1»(ref-553423-S16600645432013051700000)
2. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-553433-S31264435182013051700000)
3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Disconnect the connector. Loosen the hose clamp and disconnect the air cleaner hose assembly. Remove the 2 clamps and air cleaner cap subassembly.
4. REMOVE INLET AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 31»(ref-553433-S31264435182013051700000)
5. REMOVE AIR CLEANER CASE Remove the air cleaner filter element sub-assembly. Disconnect the water hose from the 3 clamps. Remove the 3 bolts and air cleaner case.
6. REMOVE AIR CLEANER HOSE ASSEMBLY Loosen the hose clamp and separate the ventilation hose. Unlock the hose clamp and remove the air cleaner hose assembly.
7. REMOVE THROTTLE BODY ASSEMBLY Type A: Disconnect the connector. Disconnect the No. 1 water by-pass hose and No. 2 water by-pass hose. Remove the 2 bolts, 2 nuts and throttle body assembly. Remove the gasket from the intake manifold. Type B: Disconnect the connector. Disconnect the No. 1 water by-pass hose and No. 2 water by-pass hose. Remove the 4 bolts and throttle body assembly Remove the gasket from the intake manifold.

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1. INSPECT THROTTLE BODY ASSEMBLY Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Component without harness connected (Throttle Body) Standard Resistance Tester Connection Condition Specified Condition 1 (M-) - 2 (M+) 20°C (68°F) 0.3 to 100 ohms If the result is not as specified, replace the throttle body assembly.

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1. INSTALL THROTTLE BODY ASSEMBLY Type A: Install a new gasket onto the intake manifold. HINT: Orient the protrusion of the gasket as shown in the illustration. TEXT IN ILLUSTRATION *a Protrusion Install the throttle body assembly with the 2 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 1 water by-pass hose and No. 2 water by-pass hose. Connect the connector Type B: Install a new gasket onto the intake manifold. HINT: Orient the protrusion of the gasket as shown in the illustration. TEXT IN ILLUSTRATION *a Protrusion Install the throttle body assembly with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 1 water by-pass hose and No. 2 water by-pass hose. Connect the connector
2. INSTALL AIR CLEANER HOSE ASSEMBLY Install the air cleaner hose assembly and lock the hose clamp. Connect the ventilation hose.
3. INSTALL AIR CLEANER CASE Install the air cleaner case with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Install the water hose to the 3 hose clamps. Install the air cleaner filter element sub-assembly.
4. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 70»(ref-553433-S18020678732013051700000)
5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Install the air cleaner cap sub-assembly with the 2 clamps. Connect the air cleaner hose assembly and tighten the hose clamp. Connect the connector.
6. ADD COOLANT (for Engine) . Refer to «REPLACEMENT - Step 2»(ref-553423-S16600645432013051700000)
7. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-553441-S40353769422013051700000)
8. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 99»(ref-553433-S18020678732013051700000)
9. PERFORM INITIALIZATION NOTE: Be sure to perform this procedure after reassembling the throttle body assembly, removing and reinstalling any throttle body component or replacing the ECM. Disconnect the cable from the negative (-) auxiliary battery terminal. Wait at least 60 seconds and reconnect the cable. Connect the Techstream to the DLC3 and clear the DTCs. Refer to «DTC CHECK / CLEAR»(ref-553305-S22976237422013051700000) . Set the vehicle to the inspection mode. Refer to «INSPECTION MODE PROCEDURE»(ref-553290-S22500871302013051700000) . Start the engine without operating the accelerator pedal and check that the MIL is not illuminated and that the idle speed is within the specified range when the air conditioning is switched off after the engine is warmed up. Standard Condition Engine Idle Speed A/C switched off 950 to 1050 rpm NOTE: If the accelerator pedal is operated, perform the above steps again. Be sure to perform this step with all accessories off. Make sure that park (P) is selected. Perform a road test and confirm that there are no abnormalities.

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1. PRECAUTION NOTE: After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to «PRECAUTION»(ref-553290-S20522462032013051700000) . HV battery learning values are stored in the power management control ECU and ECM to display "HAVE TRACTION BATTERY INSPECTED" on the multi-information display. When either of these ECUs is replaced, the new ECU receives the HV battery learning value data from the other ECU and updates the information. NOTE: Do not replace the power management control ECU and ECM at the same time as it clears the HV battery learning values. However, if it is necessary to replace both ECUs at the same time, replace them by following the procedure below. Do not replace the power management control ECU or ECM with used ones from other vehicles. Procedure when replacing both power management control ECU and ECM: Disconnect the cable from the negative (-) auxiliary battery terminal. Replace either of the ECUs. Connect the cable to the negative (-) auxiliary battery terminal. Turn the power switch on (READY) and wait for 5 minutes or more. Turn the power switch off and disconnect the cable from the negative (-) auxiliary battery terminal. Replace the other ECU. Connect the cable to the negative (-) auxiliary battery terminal. Check that the power switch can be turned on (READY). HINT: If the power management control ECU and ECM are replaced at the same time without following the above procedure, replace either of the ECUs with its original one and then replace it again by following the above procedure. If the correct procedure is not followed, perform the procedure again from the beginning.
2. REMOVE REAR NO. 3 FLOOR BOARD . Refer to «REMOVAL - Step 2»(ref-553447-S25298351662013051700000)
3. REMOVE DECK FLOOR BOX RH . Refer to «REMOVAL - Step 3»(ref-553447-S25298351662013051700000)
4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-553290-S07508891342013051700000) .
5. SEPARATE INVERTER RESERVE TANK ASSEMBLY Remove the 2 bolts and separate the inverter reserve tank assembly.
6. REMOVE ECM Remove the No. 1 relay block cover. Disconnect the 3 wire harness connectors. Disengage the 2 claws, push up the engine room wire harness and separate it from the engine room relay block. Disengage the 2 claws and push up the side cover to remove it. Loosen the bolt and separate the No. 2 engine room wire. Disconnect the 2 ECM connectors. Disconnect the 2 wire harness clamps. Push the locks on the 2 levers, then raise the levers, and disconnect the 2 ECM connectors. NOTE: After disconnecting the connectors, make sure that dirt, water or other foreign matter does not contact the connecting parts of the connectors. Separate the 3 wire harness clamps. Remove the 2 bolts and ECM with 2 ECM brackets.

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1. INSTALL ECM Install the ECM with the 2 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Install the 3 wire harness clamps. Connect the 2 ECM connectors. Connect the 2 ECM connectors and lower the 2 levers. NOTE: When connecting the connectors, make sure that dirt, water or other foreign matter does not get caught between the connectors and other parts. Make sure that the 2 levers are securely locked. Install the 2 wire harness clamps. Install the No. 2 engine room wire with the bolt. Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) Slide the side cover down and engage the 2 claws to install it. Slide the engine room wire harness down and engage the 2 claws to install it. Connect the 3 wire harness connectors. Install the No. 1 relay block cover.
2. INSTALL INVERTER RESERVE TANK ASSEMBLY Install the inverter reserve tank assembly with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-553290-S07508891342013051700000) .
4. INSTALL DECK FLOOR BOX RH . Refer to «INSTALLATION - Step 54»(ref-553447-S17265292782013051700000)
5. INSTALL REAR NO. 3 FLOOR BOARD . Refer to «INSTALLATION - Step 55»(ref-553447-S17265292782013051700000)

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Note. Perform the mass air flow meter inspection in accordance with the following procedure. Replace the mass air flow meter only when foreign matter adheres to the sensor and the MAF value in the Data List (with the engine stopped) is not within the normal operating range.

1. INSPECT MASS AIR FLOW METER Read the values using the Techstream (MAF). NOTE: Perform the inspection with the vehicle indoors and on a level surface. Perform the inspection of the mass air flow meter while it is installed into the air cleaner case (installed on the vehicle). During the test, do not use an exhaust air duct on the exhaust pipe. Connect the Techstream to the DLC3. Turn the power switch on (IG) (do not run the engine). Turn the Techstream on. Enter the following menus: Powertrain / Engine and ECT / Data List / MAF. Wait 30 seconds, and read the values on the Techstream. Standard Condition Tester Display Condition Standard Condition MAF Engine not running 30 seconds after power switch is turned on (IG) Less than 0.25 g/sec If the result is not as specified, replace the mass air flow meter. If the result is within the specified range, remove and inspect the mass air flow meter. Refer to «INSPECTION»(ref-553431-S41373481642013051700000) .

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1. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 29»(ref-553433-S31264435182013051700000)
2. REMOVE MASS AIR FLOW METER Disconnect the mass air flow meter connector. Remove the 2 screws and the mass air flow meter.

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1. INSPECT MASS AIR FLOW METER Perform a visual check for any foreign matter on the platinum hot wire (heater) of the mass air flow meter shown in the illustration. TEXT IN ILLUSTRATION *1 Platinum Hot Wire (Heater) Result There is no foreign matter. If the result is not as specified, replace the mass air flow meter. Measure the resistance according to the value(s) in the table below. TEXT IN ILLUSTRATION *1 Mass Air Flow Meter Standard Resistance Tester Connection Condition Specified Condition 1 (THA) - 2 (E2) -20°C (-4°F) 13.6 to 18.4 kohms 20°C (68°F) 2.21 to 2.69 kohms 60°C (140°F) 0.49 to 0.67 kohms