Toyota 2008 Camry User manual

i
Petrol-Electric
Hybrid Synergy Drive
AHV40 Series

ii
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.
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:
•Toyota Camry identification.
•Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle the Hybrid Camry-electric
vehicle as safely as the dismantling of a conventional petrol engine automobile.
©2010 Toyota Motor Corporation Australia Limited
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation

iii
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 ............................ 14
Necessary items .........................................................................................................................................14
SPILLAGE................................................................................................................................... 15
DISMANTLING A VEHICLE ....................................................................................................... 16
REMOVAL OF HV BATTERY ..................................................................................................... 19
HV battery removal .....................................................................................................................................19
HV Battery Caution Label ...........................................................................................................................31

1
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. Petrol stored in the fuel tank for the petrol 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 petrol engine also powers an electric generator to recharge the battery
pack; unlike a pure all electric vehicle, the Hybrid Camry 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 Hybrid Camry operates in various
driving modes.
During light acceleration at low speeds, the vehicle is powered by the electric motor.
The petrol engine is shut off.
During normal driving, the vehicle is powered mainly by the petrol engine. The
petrol engine also powers the generator to recharge the battery pack.
During full acceleration, such as climbing a hill, both the petrol 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 petrol engine and electric motor are off, however the
vehicle remains on and operational.


2
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.
Example VIN:
6T153FK4#########
A Hybrid Camry is identified by the first 6 alphanumeric characters, 6T153F.
Front Passenger Door Pillar and Under Front Right Side Seat

3
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.
Exterior Rear and Passenger Side View
Exterior Passenger Side View
Exterior Front View


 HYBRID
SYNERGY
DRIVE
 Camry
 HYBRID

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 litre per 100 km consumption is used. A
multi-information display showing energy flow is provided in the centre of the speedometer.
Interior View
Instrument Cluster View



5
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



6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volts
Auxiliary
Battery 
Boot A lead-acid battery that supplies power to the low voltage devices.
Hybrid
Vehicle (HV)
Battery Pack

Boot 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 coloured 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.
Petrol
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
Boot
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 petrol via single fuel line to the engine. The
fuel line is routed along the driver side under the floor pan.

7
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











8
Hybrid Synergy Drive Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, the petrol engine does not idle like a typical automobile and will start and stop
automatically. It is important to recognise 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 petrol engine may be off and the engine compartment is silent.
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. The vehicle is shut off when the READY indicator is off.
The vehicle may be powered by:
1. The electric motor only.
2. The petrol engine only.
3. A combination of both the electric motor and the petrol 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 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. The metal case is isolated from high voltage and concealed by fabric
covers.
•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.
•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 118 x 20 x 276 mm
NiMH module weight 1.0 kg
NiMH battery Pack dimensions 190 x 850 x 495 mm
NiMH battery Pack weight 52 kg
Components to Which High Voltage is Applied
•Electric Motor •Power Cables
•Inverter/Converter •DC-DC Converter
•A/C Compressor •Electric Generator

10
HV Battery Pack Recycling
The HV battery pack is recyclable. Contact the nearest Toyota dealer.
244.8 Volts HV Battery Pack HV Battery Pack
(Viewed from the Boot)

11
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. 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
•A high voltage fuse provides short circuit protection in the HV battery pack.
•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.
•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.
•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.
•The HV battery pack relays will automatically open to stop the electrical flow in a collision
sufficient to activate the SRS.

12
Service Plug
•The high-voltage circuit is cut by removing service plug (See page 16).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)






0 Volts AC
3-Phase
A/C Compressor
Inverter/
Converter
Hybrid Vehicle Computer
HV Battery
DC/DC
Converter
Electric Motor
Generato
r
Volts DC
Volts DC
12 Volts
Battery

13
High Voltage Safety System – Vehicle On and Operational (READY-ON)
Inverter/
Converter
DC/DC
650 Volts AC
3-Phase
A/C Compressor
Hybrid Vehicle Computer
12 Volts
Battery
DC/DC
Converter
Volts DC
Volts DC
Generato
r
Electric Motor
HV Battery

14
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
•Protective clothing (insulated gloves, rubber gloves, safety goggles, and safety
shoes).
•Vinyl tape for insulation.
•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.

15
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 neutralise a lead-acid battery electrolyte spill, a dilute boric
acid solution or vinegar can be used to neutralise a NiMH battery electrolyte spill.
In an emergency, Toyota Material Safety Data Sheets (MSDS) are available with the Hybrid
Vehicle Dismantling Manual.
•Handle NiMH electrolyte Spills Using The following Personal Protective Equipment
(PPE):
•Splash shield or safety goggles. Folding down helmet shields is not acceptable for
alkaline spillage.
•Rubber, latex or Nitrile gloves.
•Apron suitable for alkaline.
•Rubber boots.
•Neutralise NiMH Electrolyte
•Use a boric acid solution or vinegar.
•Boric acid solution - 800 grams boric acid to 20 litres water or 5.5 ounces boric
acid to 1 gallon of water

16
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