4th-Generation Toyota Prius Teardown (Part 1)

Powertrain units miniaturized and lightened to achieve 40km/liter fuel economy

2016/02/29

Table of contents

Summary
Powertrain units improved to achieve a JC08 mode fuel economy of 40km/liter
High performance engine with up to 40% thermal efficiency
New structure for the hybrid transaxle (loss reduced by about 20%, length shortened by 47mm)
Miniaturized power control unit
Compact, high-performance lithium-ion drive battery pack

Summary

In January 2016, the Hiroshima Industrial Promotion Organization performed a teardown analysis of the all-new Toyota Prius (launched in December 2015). The Prius has been reborn as a completely new car through significant changes such as the adoption of a newly-designed hybrid transaxle, and the use of the new TNGA (Toyota New Global Architecture) platform, all of which was done with the aim of achieving a JC08 mode fuel economy of 40.8km/liter (E grade) and improving the driving performance. (The analysis was performed on the A grade Prius, which has a fuel economy of 37.2km/liter.)

Part 1 of the teardown report will focus on the powertrain units and other technologies that contribute to increasing the fuel economy. Part 2 will look at the TNGA, and the technical innovations that changed the Prius from what was merely a fuel-efficient car, to a fuel-efficient and power-efficient car.

Previous teardown reports:

Daihatsu Move (Feb./Mar. 2015)
(Part 1) Suppliers list, chassis, seats, and electrical components
(Part 2) Turbo engine and CVT with 3-shaft gear train has lightweight and compact design
(Part 3) Linear body structure optimizes space

VW Polo (Dec. 2014)
(Part 1) Engine compartment and driver's seat area
(Part 2) 1.2-liter TDI diesel engine and suspensions

Nissan Note (Sep. 2014)
(Part 1) Major safety technology and advanced driver assistance systems
(Part 2) Drive unit and supercharger

Honda Accord Hybrid (Feb. 2014)
(Part 1) Sport Hybrid i-MMD PCU and vehicle chassis components
(Part 2) SPORT HYBRID i-MMD Battery components and electric servo brake system
(Part 3) SPORT HYBRID i-MMD drive unit

Honda Fit Hybrid (Dec. 2013)
(Part 1) Battery components & brake system
(Part 2) Engine and transmission

Toyota Aqua (Nov. 2012)
(Part 1) Part suppliers and battery components
(Part 2) Hybrid systems behind the 35.4km/liter (53 mpg city) car

Nissan Leaf
(Part 1) Nissan Leaf teardown (Mar. 2012)
(Part 2) main components disassembled (Sep. 2012)
(Part 3) body cutaway (Nov. 2012)

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