Toyota Camry Dismantling Manual
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Toyota Camry Dismantling Manual

Gasoline-electric hybrid synergy drive
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See also: Owner's Manual , Dismantling Manual
Gasoline-Electric
Hybrid Synergy Drive
AVV50 Series

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Summary of Contents for Toyota Camry

  • Page 1 Gasoline-Electric Hybrid Synergy Drive AVV50 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Camry gasoline-electric hybrid vehicles. Camry hybrid dismantling procedures are similar to other non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota Camry hybrid, as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    Table of Contents About the Camry Hybrid..........................1 Camry Hybrid Identification........................2 Exterior .................................3 Camry Hybrid 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 HV Battery Pack............................9...

  • Page 5: About The Camry Hybrid

    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 Hybrid Identification

    Camry Hybrid Identification In appearance, the 2012 model year 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, right side floor and on the left side B pillar.

  • Page 7: Exterior

    Camry Hybrid Identification (Continued) Exterior logos on the luggage compartment door. logo on each front fender. General U.S.A., Canada and South Korea Exterior Left Side View General U.S.A., Canada and South Korea Exterior Front View U.S.A., Canada and South Korea...

  • Page 8: Camry Hybrid Identification (Continued)

    Camry Hybrid Identification (Continued) Interior Instrument cluster (speedometer, READY light, shift state indicators, warning lights) located in the center of the dash and near the base of the windshield. Hint: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.

  • Page 9: Engine Compartment

    Camry Hybrid Identification (Continued) Engine Compartment 2.5-liter aluminum alloy gasoline engine. Logo on the plastic engine cover. Orange colored high voltage power cables. Engine Compartment View Power Cables...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description 12 Volt Right Side of A lead-acid battery that supplies power to the low voltage Auxiliary Battery Trunk devices. Hybrid Vehicle Trunk, Mounted to 244.8 Volt Nickel Metal Hydride (NiMH) battery pack (HV) Battery Pack Cross Member consisting of 34 low voltage (7.2 Volt) modules connected...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 155 hp (116 kW), 2.5-liter Aluminum Alloy Engine (U.S.A., Canada, South Korea) 158 hp (118 kW), 2.5-liter Aluminum Alloy Engine (General) Electric Motors 141 hp (105 kW) , Permanent Magnet Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 244.8 Volt Sealed NiMH Battery Curb Weight: 3,483 lbs/1,580 kg...

  • Page 12: Hybrid Synergy Drive Operation

    Vehicle Operation • With the Camry hybrid, the gasoline 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 Camry hybrid features 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 rigidly mounted to the trunk floor pan cross member behind the rear seat.

  • Page 14: Hv Battery Pack Recycling

    Auxiliary Battery • The Camry hybrid also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle. As with other conventional vehicles, the auxiliary battery is grounded to the metal chassis of the vehicle.

  • 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 inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 244.8 to 650 Volts DC.

  • Page 16: Service Plug Grip

    High Voltage Safety (Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 15). 12 Volt Volt DC Hybrid Vehicle Computer Auxiliary Battery Compressor Electric Inverter/ Generator Converter Electric Volt DC Motor 3-Phas HV Battery Assembly High Voltage Safety System –...

  • 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: Spills

    Spills The Camry hybrid contains the same common automotive fluids used in other non-hybrid Toyota vehicles, with the exception of the 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 The Vehicle

    Dismantling the vehicle The following 2 pages contain general instructions for use when working on a Camry hybrid. Read these instructions before proceeding to the HV battery removal instructions on page 18. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 20 Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 11. With the exception of the HV battery, remove parts by following procedures which are similar to conventional Toyota vehicles. For the removal of the HV battery, refer to the following pages.

  • Page 22: Removal Of Hv Battery

    Removal of HV battery WARNING: ・ Be sure to wear insulated gloves when handling high-voltage parts. ・ Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work.
  • Page 23 6. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER (1) Disengage the 8 fasteners. (2) Disengage the 3 claws and remove the luggage compartment front trim cover. 7. REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL Remove the 2 nuts and No. 8 hybrid vehicle battery shield panel.
  • Page 24 9. REMOVE CONNECTOR COVER ASSEMBLY Caution: Wear insulated gloves. Remove the 2 bolts and connector cover assembly. 10. CHECK TERMINAL VOLTAGE Check voltage at the terminals in inspection point in the power control unit. Caution: Wear insulated gloves. To prevent serious injury or death, do not proceed with dismantling of the HV system until the voltage at the terminals in the inspection point is 0 V.
  • Page 25 12. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (1) Push the 2 pins and remove the 2 No. 1 luggage compartment trim hooks. 13. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH (1) Remove the 3 clips. (2) Disengage the fastener and remove the luggage compartment inner trim cover LH.
  • Page 26 16. REMOVE REAR SEAT CUSHION LOCK HOOK (1) Disengage the hook of the seat cushion from the vehicle body as shown in the illustration. Hint: Use the same procedure for the RH side and the LH side. 17. REMOVE REAR SEATBACK ASSEMBLY (1) Disengage the 3 fasteners as shown in the illustration.
  • Page 27 Disengage the 2 fasteners as shown in the illustration. (3) Remove the 2 bolts and rear seatback assembly 20. REMOVE REAR SIDE SEATBACK ASSEMBLY LH (1) Disconnect each connector. (2) Remove the 2 bolts. (3) Disengage the hook and remove the rear side seatback assembly LH.
  • Page 28 23. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (1) Remove the 2 nuts and child restraint seat anchor bracket sub-assembly LH. 24. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH AND RH 25. REMOVE ROOF SIDE INNER GARNISH LH AND RH 26.
  • Page 29 28. REMOVE ROOM PARTITION BOARD (U.S.A., Canada and South Korea) Using a clip remover, remove the 4 clips. (2) Disengage the 5 clips and remove the No. 1 room partition board. (General) Using a clip remover, remove the clip. (2) Disengage the 5 claws and clip, and remove the room partition board LH.
  • Page 30 30. REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL Caution: Wear insulated gloves for the following 2 steps. Remove the 3 clips and No. 1 hybrid battery intake duct. Hint: Insert the projecting part of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.
  • Page 31 (2) Disconnect the 2 connectors. 33. REMOVE HV BATTERY Caution: Wear insulated gloves. Notice: Since the HV battery is very heavy, 2 people are needed to remove the HV battery. When removing the HV battery, do not damage the parts around it. Remove the 6 bolts from the HV battery.
  • Page 32 Pull the HV battery toward the center of the luggage compartment. Remove the 2 nuts and No. 2 hybrid vehicle battery upper cover bracket. (4) Remove the clip. (5) Disengage the 2 claws and remove the No. 2 hybrid battery intake duct. (6) Disconnect the connector from the battery cooling blower assembly.
  • Page 33 (10) Using a suitable adaptor such as a rope, remove the HV battery while tilting the HV battery. 34. The HV battery pack is recyclable. Contact your Toyota distributor (if included on the HV battery caution label) or contact the nearest Toyota dealer (see the next 2 pages for samples of the HV battery caution label).

  • Page 34: Hv Battery Caution Label

    HV Battery Caution Label 1. For U.S.A. 2. For CANADA...
  • Page 35 3. For Korea and General...

This manual is also suitable for:

Camry avv50 series2012 camry hybrid 4-door sedan

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