Toyota 2008 Camry User manual

Gasoline-Electric
Hybrid Synergy Drive
AHV40 Series

ii
Foreword
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.
High voltage electricity powers the electric motor, generator, A/C compressor, and
inverter/converter. All other automotive electrical devices such as the headlights, power steering,
horn, radio, and gauges are powered from a separate 12 Volts battery. Numerous safeguards have
been designed into the CAMRY to help ensure the high voltage, approximately 245 Volts, Nickel
Metal Hydride (NiMH) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
Additional topics contained in the guide include:
N Toyota CAMRY identification.
N Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle the CAMRY
hybrid-electric vehicle as safely as the dismantling of a conventional gasoline engine automobile.
¤2006 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation

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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
HV Battery Pack Recycling......................................................................................................................... 10
High Voltage Safety ...................................................................................................................... 11
Service Plug ............................................................................................................................................... 12
Precaution to be observed when dismantling the vehicle ............................................................... 13
Necessary items ......................................................................................................................................... 13
Spillage......................................................................................................................................... 14
Dismantling a vehicle.................................................................................................................... 15
Removal of HV battery ................................................................................................................. 18
HV battery removal..................................................................................................................................... 18
HV Battery Caution Label ........................................................................................................................... 30

1
About the CAMRY
The CAMRY hybrid sedan joins the PRIUS and HIGHLANDER hybrid as a hybrid
model for Toyota. Hybrid Synergy Drive means that the vehicle contains a gasoline
engine and an electric motor for power. The two hybrid power sources are stored on
board the vehicle:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the electric
motor.
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.
Depending on the driving conditions, one or both sources are used to power the vehicle.
The following illustration demonstrates how the CAMRY hybrid operates in various
driving modes.
During light acceleration at low speeds, the vehicle is powered by the electric
motor. The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the gasoline engine.
The gasoline engine also powers the generator to recharge the battery pack.
During full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the front wheels to produce electricity that recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor are off,
however the vehicle remains on and operational.
H

2
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.
Example VIN: JTNBB46S730020208
4T1BB46S7U0031258
A CAMRY hybrid is identified by the first 6 alphanumeric characters
JTNBB4 and 4T1BB4
Driver Side Windshield
Base of Driver Side B Pillar

3
Exterior
CAMRY logo on the trunk door.
HYBRID SYNERGY DRIVE logo on the trunk lid.
HYBRID logo on each front fender.
Gasoline fuel filler door located on the driver side rear quarter panel.
Exterior Rear and Passenger Side View
Exterior Driver Side View
Exterior Front View

 HYBRID
SYNERGY
DRIVE

 CAMRY 

4
CAMRY Identification (Continued)
Interior
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 miles per gallon (mpg) consumption is used.
A multi-information display showing energy flow is provided in the center of the
speedometer.
Interior View
Instrument Cluster View



5
Engine Compartment
2.4-liter aluminum alloy gasoline engine.
High voltage inverter/converter assembly with logos on the cover.
HYBRID SYNERGY DRIVE Logo on
Engine cover
Engine Compartment



6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volts
Auxiliary
Battery 
Trunk A lead-acid battery that supplies power to the low voltage devices.
Hybrid
Vehicle (HV)
Battery Pack

Trunk Area, Mounted
to Cross Member and
behind Rear Seat
244.8 Volts Nickel Metal Hydride (NiMH) battery pack consisting
of 34 low voltage (7.2 Volts) modules connected in series.
Power
Cables 
Under Carriage and
Engine Compartment
Orange colored power supply cables carry high voltage Direct
Current (DC) between the HV battery pack, inverter/converter, and
A/C compressor. These cables also carry 3-phase Alternating
Current (AC) between the inverter/converter, electrical motor, and
generator.
Inverter/
Converter 
Engine Compartment Boosts and inverts the high voltage electricity from the HV battery
pack to 3-phase AC electricity that drives the electric motor. The
inverter/converter also converts AC electricity from the electric
generator and electric motor (regenerative braking) to DC that
recharges the HV battery pack.
Gasoline
Engine 
Engine Compartment Provides two functions: 1) Powers vehicle. 2) Powers generator to
recharge the HV battery pack. The engine is started and stopped
under control of the vehicle computer.
Electric
Generator 
Transaxle 3-phase high voltage AC generator that is contained in the
transaxle and recharges the HV battery pack.
Electric
Motor 
Transaxle 3-phase high voltage AC permanent magnet electric motor
contained in the transaxle. Used to power the front wheels.
A/C
Compressor

Engine Compartment 3-phase high voltage AC electrically driven motor compressor.
12 Volts
DC-DC
Converter 
Inside HV Battery
Pack Assembly in
Trunk
Converts 244.8 Volts DC from the HV battery pack to 12 Volts DC
for low voltage vehicle power.
Fuel Tank
and Fuel
Line 
Undercarriage,
Driver Side
The fuel tank provides gasoline via single fuel line to the engine.
The fuel line is routed along the driver side under the floor pan.

7
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
Liters/100 km: 5.9 / 6.3 (City/Hwy) liters/100 km
Frame Material: Steel Unibody
Body Material: Steel Panels
Power Cable


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
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8
Hybrid Synergy Drive Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, the gasoline engine does not idle like a typical automobile and will start and stop
automatically. It is important to recognize and understand the READY indicator provided in the
instrument cluster. When lit, it informs the driver that the vehicle is on and operational even
though the gasoline engine may be off and the engine compartment is silent.
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. The vehicle is shut off when the READY indicator is off.
 The vehicle may be powered by:
1. The electric motor only.
2. The gasoline engine only.
3. A combination of both the electric motor and the gasoline engine.
The vehicle computer determines the mode in which the vehicle operates to improve fuel
economy and reduce emissions. The driver cannot manually select the mode.
Instrument Cluster READY Indicator

9
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
N The HV battery pack is enclosed in a metal case and is securely mounted in the trunk area
behind the rear seat. The metal case is isolated from high voltage and concealed by
fabric covers.
N The HV battery pack consists of 34 low voltage (7.2 Volts) NiMH battery modules
connected in series to produce approximately 244.8 Volts. Each NiMH battery module is
non-spillable and sealed in a plastic case.
N The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and
sodium hydroxide. The electrolyte is absorbed into the battery cell plates and forms a gel
that will not normally leak, even in a collision.
In the unlikely event that the battery pack is overcharged, the modules vent gases directly
outside the vehicle through a vent hose.
HV Battery Pack
Battery pack voltage 244.8 V
Number of NiMH battery modules in the pack 34
NiMH battery module voltage 7.2 V
NiMH battery module dimensions 5 x 1 x 11 in.
(118 x 20 x 276 mm)
NiMH module weight 2.3 lbs (1.0 kg)
NiMH battery Pack dimensions 8 x 34 x 19 in.
(190 x 850 x 495 mm)
NiMH battery Pack weight 114.6 lbs (52 kg)
Components to Which High Voltage is Applied
N Electric Motor N Power Cables
N Inverter/Converter N DC-DC Converter
N A/C Compressor N Electric Generator

10
HV Battery Pack Recycling
N The HV battery pack is recyclable. Contact the nearest Toyota dealer, or:
United States: [phone] Canada: [phone]
244.8 Volts HV Battery Pack HV Battery Pack
(Viewed from the Trunk)

11
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. The inverter creates 3-phase AC to power the motor and generator located in the
transaxle. Power cables are routed from the inverter to each high voltage motor (electric
motor, electric generator, and A/C compressor). The following systems are intended to help
occupants in the vehicle and emergency responders safe from high voltage electricity.
High Voltage Safety System
N A high voltage fuse provides short circuit protection in the HV battery pack.
N Positive and negative high voltage power cables connected to the HV battery pack are
controlled by 12 Volt normally open relays . When the vehicle is shut off, the relays stop
electrical flow from leaving the HV battery pack.
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.
N Both positive and negative power cables are insulated from the metal chassis, so there is
no possibility of electric shock when touching the metal chassis.
N A ground fault monitor continuously monitors for high voltage leakage to the metal
chassis while the vehicle is running. If a malfunction is detected, the hybrid vehicle
computer will illuminate the master warning light in the instrument cluster and
indicate “CHECK HYBRID SYSTEM” on the multi-information display.
N The HV battery pack relays will automatically open to stop the electrical flow in a
collision sufficient to activate the SRS.

12
Service Plug
N 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)
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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.
Necessary items
N Protective clothing (insulated gloves, rubber gloves, safety goggles, and safety
shoes).
N Vinyl tape for insulation.
N Before wearing insulated the vehicle gloves, make sure that they are not cracked,
ruptured, torn, or damaged in any other way. Do not wear wet insulated gloves.

14
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. A catastrophic crash that would breach both the metal battery
pack case and the plastic battery module would be a rare occurrence.
Similar to the use of baking soda to neutralize a lead-acid battery electrolyte spill, a dilute
boric acid solution or vinegar can be used to neutralize a NiMH battery electrolyte spill.
In an emergency, Toyota Material Safety Data Sheets (MSDS) are available by contacting:
N Handle NiMH electrolyte Spills Using The following Personal Protective Equipment
(PPE):
N Splash shield or safety goggles. Folding down helmet shields is not acceptable for
alkaline spillage.
N Rubber, latex or Nitrile gloves.
N Apron suitable for alkaline.
N Rubber boots.
N Neutralize NiMH Electrolyte
N Use a boric acid solution or vinegar.
N Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric
acid to 1 gallon of water.

15
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.
1. Shut off ignition. Then disconnect the
negative (-) terminal of the auxiliary
battery.
2. Remove the service plug grip.
a) Wear insulated gloves and raise the service plug grip as shown in the illustration. Then,
remove the service plug grip.
b) Apply electrical tape to the socket of the service plug grip to insulate it.
Battery service hole cover
④
③
⑤
①
②

16
3. Carry the removed service plug in your pocket to prevent other staff from
reinstalling it while you are dismantling the vehicle.
4. Make other staff aware that a
high-voltage system is being
dismantled by using the following
sign: CAUTION: HIGH VOLTAGE.
DO NOT TOUCH DURING
OPERATION (see page 17).
5. If the service plug cannot be removed
due to damage to the rear portion of
the vehicle, remove the IGCT fuse
(30A: Green colored).
Caution:
This operation shuts off the HV system.
Be sure to wear insulated gloves
because high voltage is not shut off
inside the HV battery. When it is
possible to remove the service plug,
remove it and continue the procedure.
6. After disconnecting or exposing a high-voltage connector or terminal, insulate it
immediately using insulation tape. Before touching a bare high-voltage terminal,
wear insulated gloves.
7. Check the HV battery and nearby area for leakage. If you find any liquid, it may be
strong alkaline electrolyte. Wear
rubber gloves and goggles and
neutralize the liquid using a saturated
boric acid solution or vinegar. Then
wipe up the liquid using waste rags
etc.
a) If the electrolyte adheres to your
skin, wash the skin immediately
using a saturated boric acid
solution or a large amount of water. If the electrolyte adheres to any article
of clothing, take the clothing off immediately.
b) If the electrolyte comes into contact with your eye(s), call out loudly for help.
Do not rub your eye(s). Instead, wash the eye(s) with a dilute boric acid
solution or a large amount of water and seek medical care.
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
the following pages.
Fuse Box
IGCT
F
use