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.