Toyota Camry Dismantling Manual
Gasoline-electric hybrid synergy drive
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Summary of Contents for Toyota Camry
- Page 1 Gasoline-Electric Hybrid Synergy Drive AHV40 Series...
- Page 2 In March 2006, Toyota released the Toyota CAMRY gasoline-electric hybrid vehicle in North America. Except where noted in this guide, basic vehicle systems and features for the CAMRY hybrid are the same as those on the conventional, non-hybrid, Toyota CAMRY. To educate and assist emergency responders in the safe handling of the CAMRY hybrid technology, Toyota published this CAMRY hybrid Emergency Response Guide.
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Page 3: Table Of Contents
Table of Contents About the CAMRY .........................1 CAMRY Identification........................2 Exterior ................................. 3 CAMRY Identification (Continued) ....................4 Interior ................................4 Engine Compartment............................ 5 Hybrid Component Locations & Descriptions.................6 Specifications..............................7 Hybrid Synergy Drive Operation....................8 Vehicle Operation ............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery ...............9 Components to Which High Voltage is Applied ..................... -
Page 5: About The Camry
The result of combining these two power sources is improved fuel economy and reduced emissions. The gasoline engine also powers an electric generator to recharge the battery pack; unlike a pure all electric vehicle, the CAMRY hybrid never needs to be recharged from an external electric power source. -
Page 6: Camry Identification
CAMRY Identification In appearance, the 2007 CAMRY hybrid is nearly identical to the conventional, non-hybrid Toyota CAMRY. The CAMRY hybrid is a 4-door sedan. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl and driver door pillar. -
Page 7: Exterior
Exterior n CAMRY logo on the trunk door. o HYBRID SYNERGY DRIVE logo on the trunk lid. p HYBRID logo on each front fender. q Gasoline fuel filler door located on the driver side rear quarter panel. HYBRID SYNERGY DRIVE... -
Page 8: Camry Identification (Continued)
CAMRY Identification (Continued) Interior r The instrument cluster (speedometer, fuel gauge, and warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid CAMRY. s In place of a tachometer, a fuel meter showing miles per gallon (mpg) consumption is used. -
Page 9: Engine Compartment
Engine Compartment t 2.4-liter aluminum alloy gasoline engine. u High voltage inverter/converter assembly with logos on the cover. HYBRID SYNERGY DRIVE Logo on Engine cover Engine Compartment... -
Page 10: Hybrid Component Locations & Descriptions
Hybrid Component Locations & Descriptions Component Location Description 12 Volts Trunk A lead-acid battery that supplies power to the low voltage devices. Auxiliary Battery n Hybrid Trunk Area, Mounted 244.8 Volts Nickel Metal Hydride (NiMH) battery pack consisting Vehicle (HV) to Cross Member and of 34 low voltage (7.2 Volts) modules connected in series. -
Page 11: Specifications
Specifications Gasoline Engine: 147 hp (110 KW), 2.4-liter Aluminum Alloy Engine Electric Motor: 141 hp (105 KW), Permanent Magnet Motor Transmission: Automatic Only HV Battery: 244.8 Volts Sealed NiMH Battery Pack Curb Weight: 3,638 lbs / 1,650 kg Fuel Tank: 17.2 gals / 65 liters Fuel Economy: 40.0 / 38.0 (City/Hwy) miles/gal... -
Page 12: Hybrid Synergy Drive Operation
Vehicle Operation z With the CAMRY hybrid, the gasoline engine may stop and start at any time while the READY indicator is on. z Never assume that the vehicle is shut off just because the engine is off. Always look for the READY indicator status. -
Page 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The CAMRY hybrid contains a high voltage, Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack The HV battery pack is enclosed in a metal case and is securely mounted in the trunk area behind the rear seat. -
Page 14: Hv Battery Pack Recycling
HV Battery Pack Recycling The HV battery pack is recyclable. Contact the nearest Toyota dealer, or: United States: (800) 331-4331 Canada: (888) 869-6828 HV Battery Pack 244.8 Volts HV Battery Pack (Viewed from the Trunk) -
Page 15: High Voltage Safety
High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the battery pack, under the vehicle floor pan to the engine compartment, and connected to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 244.8 up to 650 Volts DC. -
Page 16: Service Plug
Service Plug The high-voltage circuit is cut by removing service plug (See page 15). High Voltage Safety System – Vehicle Shut Off (READY-OFF) High Voltage Safety System – Vehicle On and Operational (READY-ON) -
Page 17: Precaution To Be Observed When Dismantling The Vehicle
Precaution to be observed when dismantling the vehicle WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component. -
Page 18: Spillage
Spillage The CAMRY contains the same common automotive fluids used in other non-hybrid Toyota vehicles, with the exception of NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked. -
Page 19: Dismantling A Vehicle
Dismantling a vehicle WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or any high voltage component. - Page 20 8. Remove the parts by following the procedures which are similar to the Toyota vehicles with exception of HV battery. As for the removal of HV battery, refer to...
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Page 22: Removal Of Hv Battery
Removal of HV battery HV battery removal WARNING: ・ Be sure to wear insulated gloves when handling high-voltage parts. ・ Even if the vehicle is shut off and the relay is off, be sure to remove the service plug grip before performing any steps. ・... - Page 23 3. Remove the luggage compartment rear trim cover LH. ① Remove the luggage compartment floor mat. ② Remove the spare wheel cover clamp. ③ Remove the spare wheel cover assembly. ④ Remove the No. 1 luggage compartment trim hooks. ⑤ Remove the rear floor finish plate. ⑥...
- Page 24 4. Remove the rear side seatback assemblies LH, center and RH. ① Remove the rear seat headrest assemblies. ② Remove the rear seat cushion assembly. ③ Remove the 4 bolts on the rear side of the seatback. ④ Remove the separate type rear seatbacks LH and RH. ⑤...
- Page 25 7. Disconnect the rear seat inner with center belt assembly LH. 8. Remove the rear seat inner with center belt assembly RH. 9. Remove the roof side inner garnishes LH and RH. Disengage the 5 clips and 2 claws, and remove the roof side inner garnish.
- Page 26 11. Using a screwdriver, disengage the 4 claws and remove the rear seat shoulder belt cover. 12. Using a screwdriver, disengage the 4 claws and remove the rear seat shoulder belt hole cover. 13. Remove the package tray trim panel assembly.
- Page 27 15. Remove the room partition boards LH and RH. Remove the 4 clips and room partition board LH. Remove the 4 clips and room partition board RH. 16. Remove the No. 1 HV battery intake duct. 17. Remove the 2 bolts, clip, and No. 2 HV battery intake duct.
- Page 28 18. Remove the battery cooling blower assembly. Remove the bolt from the battery cooling blower assembly. Disconnect the connector from the battery cooling blower assembly. Remove the battery cooling blower assembly as shown in the illustration. 19. Remove the clip and No. 5 HV battery intake duct.
- Page 29 21. Remove the 2 clips and No. 4 HV battery intake duct. 22. Remove the 2 clips nut and No. 2 HV battery exhaust duct. 23. Remove the wire harness clamp Service Plug grip bracket. Using the service plug grip, release Interlock Button the interlock button.
- Page 30 24. Remove the upper battery carrier sub-assembly. Remove the 2 nuts and ground cable. Remove the 3 nuts, bolt, and upper battery carrier sub-assembly. 25. Disconnect the frame wire. Remove the battery shield contact. Remove the 2 nuts and disconnect the frame wire (High Voltage cable).
- Page 31 26. Install the spare wheel cover assembly. 27. Install the spare wheel cover clamp. 28. Install the luggage compartment floor mat. 29. Remove the HV battery. Disconnect the wire harness clamp from the No. 1 battery cover. Release the 2 claws and remove the terminal block cover.
- Page 32 Remove the grommet and battery room ventilation hose. Remove the 4 bolts from the HV battery. Remove the 2 bolts from the HV battery. Prepare a piece of cardboard of 750 mm (29.53 in.) X 500 mm (19.69 Hold Up in.) or larger.
- Page 33 HV battery while tilting the HV battery 45° at the rear end. Cardboard 30. The HV battery pack is recyclable. Contact your Toyota distributor which is found on the HV Battery Caution Label or contact the nearest Toyota Dealer. (See the next page) Caution: After removing the HV battery, do not connect the service plug to the HV battery.
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Page 34: Hv Battery Caution Label
HV Battery Caution Label For U.S.A. For CANADA...