Toyota Camry Dismantling Manual
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Toyota Camry Dismantling Manual

Toyota camry petrol-electric hybrid synergy drive dismantling manual
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See also: Owner's Manual , Maintenance Manual
Petrol-Electric
Hybrid Synergy Drive
AHV40 Series
i

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Summary of Contents for Toyota Camry

  • Page 1 Petrol-Electric Hybrid Synergy Drive AHV40 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Camry petrol-electric hybrid vehicles. Hybrid Camry dismantling procedures are similar to other non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to recognise and understand the high voltage electrical system features and specifications of the Toyota Hybrid Camry, as they may not be familiar to dismantlers.

  • 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 .....................9...

  • Page 5: About The Camry

    About the Camry The Hybrid Camry sedan joins the Prius hybrid as a hybrid model for Toyota. Hybrid Synergy Drive means that the vehicle contains a petrol engine and an electric motor for power. The two hybrid power sources are stored on board the vehicle: 1.

  • Page 6: Camry Identification

    Camry Identification In appearance, the Hybrid Camry is nearly identical to the conventional, non-hybrid Toyota Camry. The Hybrid Camry 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 on the right side floor and left side door pillar.

  • Page 7: Exterior

    Exterior Camry logo on the boot door. HYBRID SYNERGY DRIVE logo on the boot lid. HYBRID logo on each front fender. Petrol fuel filler door located on the driver passenger rear quarter panel. HYBRID SYNERGY DRIVE Camry HYBRID Exterior Rear and Passenger Side View...

  • Page 8: Camry Identification (Continued)

    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. In place of a tachometer, a fuel meter showing litre per 100 km consumption is used. A multi-information display showing energy flow is provided in the centre of the speedometer.

  • Page 9: Engine Compartment

    Engine Compartment 2.4-litre Aluminium alloy petrol engine. 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 Boot A lead-acid battery that supplies power to the low voltage devices. Auxiliary Battery Hybrid Boot 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 Petrol Engine: 110 KW, 2.4-litre Aluminium Alloy Engine Electric Motor: 105 KW, Permanent Magnet Motor Transmission: Automatic Only HV Battery: 244.8 Volts Sealed NiMH Battery Pack Curb Weight: 1,650 kg Fuel Tank: 65 litres Frame Material: Steel Unibody Body Material: Steel Panels Power Cable...

  • Page 12: Hybrid Synergy Drive Operation

    Vehicle Operation With the Hybrid Camry, the petrol engine may stop and start at any time while the READY indicator is on. 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 Hybrid Camry 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 boot 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. HV Battery Pack 244.8 Volts HV Battery Pack (Viewed from the Boot)

  • 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 coloured 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 16). HV Battery A/C Compressor Volts DC 0 Volts AC 3-Phase Electric Motor Inverter/ DC/DC Converter Converter Generator Volts DC 12 Volts Battery Hybrid Vehicle Computer High Voltage Safety System –...
  • Page 17 HV Battery A/C Compressor Volts DC 650 Volts AC 3-Phase DC/DC Electric Motor Inverter/ DC/DC Converter Converter Generator Volts DC 12 Volts Battery Hybrid Vehicle Computer High Voltage Safety System – Vehicle On and Operational (READY-ON)

  • Page 18: 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 19: 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 20: 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 21 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...

  • Page 23: 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 24 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 25 4. Remove the rear side seatback assemblies LH, centre 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 26 7. Disconnect the rear seat inner with centre belt assembly LH. 8. Remove the rear seat inner with centre 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 27 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 28 15. Remove the room partition boards LH and RH. Remove the 4 clips and room partition board LH. b) 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 29 18. Remove the battery cooling blower assembly. Remove the bolt from the battery cooling blower assembly. b) 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 30 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 31 24. Remove the upper battery carrier sub-assembly. Remove the 2 nuts and ground cable. b) Remove the 3 nuts, bolt, and upper battery carrier sub-assembly. 25. Disconnect the frame wire. Remove the battery shield contact. b) Remove the 2 nuts and disconnect the frame wire (High Voltage cable).
  • Page 32 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. b) Release the 2 claws and remove the terminal block cover.
  • Page 33 Remove the grommet and battery room ventilation hose. Remove the 4 bolts from the HV battery. g) Remove the 2 bolts from the HV battery. h) Prepare a piece of cardboard of 750 mm (29.53 in.) X 500 mm (19.69 Hold Up in.) or larger.
  • Page 34 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.

  • Page 35: Hv Battery Caution Label

    HV Battery Caution Label Hint: The label content may change due to regulatory revisions, etc.

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Ahv40 series

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