Toyota 2012 CAMRY LE User manual

Hybrid
2012 Model
2nd Generation
© 2011 Toyota Motor Corporation
All rights reserved. This document may not be
altered without the written permission of Toyota Motor Corporation.
12 Camry Hybrid ERG REV – (09/21/11)

-i-
Foreword
In May 2006, Toyota released the 1st generation Toyota Camry
gasoline-electric hybrid vehicle in North America. To educate and
assist emergency responders in the safe handling of the 1st generation
Camry hybrid technology, Toyota published the 2007 Camry hybrid
Emergency Response Guide.
With the release of the 2nd generation Camry hybrid in September 2011,
a new 2012 Toyota Camry Hybrid Emergency Response Guide was
published for emergency responders. While many features from the 1st
generation model are similar, emergency responders should recognize
and understand the new, updated features of the 2nd generation Camry
hybrid covered in this guide.
High voltage electricity powers the electric motor, generator,
inverter/converter and air conditioning compressor. All other
automotive electrical devices such as the headlights, radio, and gauges
are powered from a separate 12 Volt auxiliary battery. Numerous
safeguards have been designed into the Camry hybrid to help ensure the
high voltage, approximately 244.8 Volt, Nickel Metal Hydride (NiMH)
Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The Camry hybrid utilizes the following electrical systems:
Maximum 650 Volts AC
Maximum 27 Volts AC
Nominal 244.8 Volts DC
Nominal 12 Volts DC
2nd Generation Camry Hybrid Features:
Complete model change with a new exterior and interior design.
An Electric Power Steering (EPS) assist motor rated at 27 Volts.
A boost converter in the inverter/converter that boosts to 650 Volts
the available voltage to the electric motor.
A high voltage Hybrid Vehicle (HV) battery pack rated at 244.8
Volts.
High voltage motor driven Air Conditioning (A/C) compressor
rated at 244.8 Volts.
A body electrical system rated at 12 Volts, negative chassis ground.
Supplemental Restraint System (SRS) – dual stage frontal airbags,
front knee airbags, front and rear seat mounted side airbags, side
curtain airbags, and front seatbelt pretensioners.
High voltage electrical safety remains an important factor in the
emergency handling of the Camry Hybrid Synergy Drive. It is
important to recognize and understand the disabling procedures and
warnings throughout the guide.
Additional topics in the guide include:
Toyota Camry hybrid identification.
Major Hybrid Synergy Drive component locations and descriptions.
Extrication, fire, recovery, and additional emergency response
information.
Roadside assistance information.
2012 Model Year Camry Hybrid
(2nd Generation) 2007 – 2011 Model Year Camry Hybrid (1st Generation)
This guide is intended to assist emergency responders in the safe
handling of a Toyota Camry hybrid vehicle during an incident.
NOTE:
Emergency Response Guides for Toyota hybrid and alternative fuel
vehicles may be viewed at http://techinfo.toyota.com.

-ii-
Table of Contents Page
About the Camry Hybrid 1
Camry Hybrid Identification 2
Hybrid Synergy Drive Component Locations & Descriptions 5
SmartKeySystem 8
Hybrid Synergy Drive Operation 10
Hybrid Vehicle (HV) Battery Pack 11
27VSystem 12
Low Voltage Battery 13
High Voltage Safety 14
SRS Airbags & Seat Belt Pretensioners 15
Emergency Response 17
Extrication 17
Fire 23
Overhaul 24
Recovering/Recycling of NiMH HV Battery Pack 24
Spills 25
First Aid 25
Submersion 26
Roadside Assistance 27

-1-
About the Camry Hybrid
The Camry hybrid continues into its 2nd generation as a gasoline-
electric hybrid vehicle. Hybrid Synergy Drive means that the vehicle
contains a gasoline engine and electric motors 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 motors.
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 and to drive the motor.
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
kinetic energy from the front wheels to produce electricity that
recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric
motors are off, however the vehicle remains on and operational.

-2-
Camry Hybrid Identification
In appearance, the 2012 model year 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: 4T1BD1FK0CU001001
A Camry hybrid is identified by the first 8 alphanumeric characters
4T1BD1FK.
Driver Side Windshield Cowl and Driver Side B Pillar
Exterior
logo on the passenger side of the trunk lid.
logo on the driver side of the trunk lid.
logo on each front fender.
Gasoline fuel filler door located on the driver side rear quarter panel.
Exterior Driver Side View
Exterior Front View Exterior Rear View
Exterior Rear and Driver Side View






-3-
Camry Hybrid Identification (Continued)
Interior
The instrument cluster (READY indicator 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 hybrid system indicator is used.
NOTE:
If the vehicle is shut off, the instrument cluster gauges will be “blacked
out”, not illuminated.
Interior View
Instrument Cluster View



READY Indicator

-4-
Camry Hybrid Identification (Continued)
Engine Compartment
2.5-liter aluminum alloy gasoline engine.
Logo on the plastic engine cover.
Engine Compartment View



-5-
Hybrid Synergy Drive Component Locations &
Descriptions
Component Location Description
12 Volt
Auxiliary
Battery 
Trunk Passenger
Side 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 Volt Nickel Metal Hydride (NiMH) battery
pack consisting of 34 low voltage (7.2 Volt)
modules connected in series.
Power Cables
Undercarriage
and Engine
Compartment
Orange colored power 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,
electric 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 motors. The
inverter/converter also converts AC electricity
from the electric generator and electric motors
(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
Motor Engine Compartment 3-phase high voltage AC motor contained in the front transaxle. It is used to power the front
wheels.
Electric
Generator Engine Compartment 3-phase high voltage AC generator that is contained in the front transaxle and recharges the
HV battery pack.
A/C
Compressor
(with
Inverter) 
Engine
Compartment 3-phase high voltage AC electrically driven motor compressor.
Hybrid Synergy Drive Components
Components (Top View) and High Voltage Power Cables
















-6-
Hybrid Synergy Drive Component Locations &
Descriptions (Continued)
Component Location Description
Fuel Tank and
Fuel Line Undercarriage and Center The fuel tank provides gasoline via a fuel line to the engine. The fuel line is routed under
the center of the vehicle.
Fuel Tank and Fuel Line


-7-
Hybrid Synergy Drive Component Locations &
Descriptions (Continued)
Key Specifications:
Gasoline Engine: 155 hp (116 kW), 2.5-liter Aluminum Alloy Engine
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: 3,441 lbs/1,561 kg
Fuel Tank: 17.2 gals/65.0 liters
Fuel Economy
Ratings: 43/39 (City/Hwy) miles/gal
4.5/4.9 (City/Hwy) liters/100 km
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 standard
Steel Unibody

-8-
Smart Key System
The Camry hybrid smart key system consists of a smart key transceiver
that communicates bi-directionally, enabling the vehicle to recognize the
smart key in proximity to the vehicle. Once recognized, the smart key
will allow the user to lock and unlock the doors without pushing smart
key buttons, and start the vehicle without inserting it into an ignition
switch.
Smart key features:
Passive (remote) function to lock/unlock the doors, unlock the trunk,
and start the vehicle.
Wireless transmitter buttons to lock/unlock all 4 doors, and unlock
the trunk.
Hidden metal cut key to lock/unlock the doors and glove box.
Door (Lock/Unlock)
There are several methods available to lock/unlock the doors.
Pushing the smart key lock/unlock buttons will lock/unlock all doors.
Touching the sensor on the backside of the driver door exterior handle, with
the smart key in proximity to the vehicle, unlocks the driver door. Touching
the sensor on the backside of the passenger door exterior handle, with the
smart key in proximity to the vehicle, unlocks all doors. Touching the lock
sensor on either front door, with the smart key in proximity to the vehicle,
locks all doors.
Inserting the hidden metal cut key in the driver door lock and turning
clockwise once unlocks the driver door, twice unlocks all doors. To lock
all doors turn the key counter clockwise once. Only the driver door
contains an exterior door lock for the metal cut key.
Trunk (Unlock)
There are several methods available to open the trunk.
Pushing the smart key trunk opener button.
Operating the trunk lock release lever located on the floor next to the driver
seat.
Pushing the trunk opener switch with the smart key in proximity to the
vehicle.
Smart Key (Fob) Hidden Metal Cut Key for Door Lock
Driver Door Unlock Touch Sensor and
Lock Touch Sensor Front Driver Door Lock
Trunk Opener Switch Trunk Lock Release Lever
Release Button
Use the Hidden Metal Cut Key
Lock Touch
Sensor
Unlock Touch
Sensor

-9-
Smart Key System (Continued)
Vehicle Starting/Stopping
The smart key has replaced the conventional metal cut key, and the power
button has replaced the ignition switch. The smart key only needs to be in
proximity to the vehicle to allow the system to function.
With the brake pedal released, the first push of the power button operates
the accessory mode, the second push operates the ignition-on mode, and the
third push turns the ignition off again.
Ignition Mode Sequence (brake pedal released):
Starting the vehicle takes priority over all other ignition modes and is
accomplished by depressing the brake pedal and pushing the power button
once. To verify the vehicle has started, check that the READY light is
illuminated in the instrument cluster.
If the internal smart key battery is dead, use the following method to start
the vehicle.
1. Touch the Toyota emblem side of the smart key to the power button.
2. Within the 5 seconds after the buzzer sounds, push the power button
with the brake pedal depressed (the READY light will illuminate).
Once the vehicle has started and is on and operational (READY-ON), the
vehicle is shut off by bringing the vehicle to a complete stop, placing the
gearshift lever in Park, and then depressing the power button once.
To shut off the vehicle before coming to a stop in an emergency, push and
hold down the power button for more than 3 seconds. This procedure may
be useful at an accident scene in which the READY indicator is on, and the
drive wheels remain in motion.
Ignition Mode Multi-information Display
(Instrument Cluster)
Off -
Accessory POWER ON
Ignition-On POWER ON
Brake Pedal Depressed Smart Key Symbol
Vehicle Started (READY-ON) -
Malfunction Warning Message
POWER ON & Smart Key Symbol
(Multi-information Display) Ignition Modes (Brake Pedal Released)
Starting Sequence
(Brake Pedal Depressed) Smart Key Recognition (When Smart Key Battery is Dead)
Button Push Button Push
Button Push
Vehicle Off Accessory Ignition-On
POWER
ON

-10-
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 motors only.
2. A combination of both the electric motors and the gasoline engine.
The vehicle computer determines the mode in which the vehicle operates in
order to improve fuel economy and reduce emissions. Two new features on
the 2012 Camry hybrid are EV (Electric Vehicle) mode and ECO
(Economy) mode:
1. EV Mode: When activated, and certain conditions have been met,
the vehicle operates with the electric motor powered by the HV
battery.
2. ECO Mode: When activated, this mode helps enhance fuel
economy on trips that involve frequent braking and acceleration.
Vehicle Proximity Notification System
A new feature on the 2012 Camry hybrid is the vehicle proximity notification
system that emits a sound when the vehicle is driven using only the electric
motor at speeds less than 25 km/h (15 mph). The sound is intended to notify
pedestrians that the vehicle is approaching.
Instrument Cluster READY Indicator
EV Mode Switch/ECO Mode Switch
Vehicle Proximity Notification System
ECO Mode
Switch EV Mode
Switch

-11-
Hybrid Vehicle (HV) Battery Pack
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. The metal case is
isolated from high voltage and concealed by fabric covers in the trunk.
The HV battery pack consists of 34 low voltage (7.2 Volt) NiMH battery
modules connected in series to produce approximately 244.8 Volts. Each
NiMH battery module is non-spillable and sealed in a metal 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 will not normally leak, even in a collision.
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 11 x 0.8 x 4.6 in
(285 x 19.6 x 117.8 mm)
NiMH module weight 2.3 lbs (1.04 kg)
NiMH battery pack dimensions 32 x 17.5 x 12.8 in
(817 x 445 x 325 mm)
NiMH battery pack weight 102.5 lbs
(46.5 kg)
Components Powered by the HV Battery Pack
HV Battery Pack Recycling
The HV battery pack is recyclable. Contact the nearest Toyota dealer or:
United States: [phone]
Canada: (888) TOYOTA 8 [[phone]]
HV Battery Pack

Electric Motor

Power Cables
Inverter/Converter Electric Generator
A/C Compressor

-12-
27 Volt System
The Camry hybrid is equipped with a 27 Volt AC assist motor for the Electric
Power Steering (EPS) system. The EPS computer generates 27 Volts from the
12 Volt system. The 27 Volt wires are isolated from the metal chassis and
routed a short distance from the EPS computer to the EPS assist motor in the
steering column.
NOTE:
27 Volts AC has a higher arc potential than 12 Volts DC.
27 Volt Electric Power Steering System
Electric Power
Steering ECU
Assist Motor

-13-
Low Voltage Battery
Auxiliary Battery
The Camry hybrid contains a lead-acid 12 Volt auxiliary battery. The 12
Volt auxiliary battery powers the vehicle’s electrical system similar to a
conventional vehicle. As with conventional vehicles, the negative terminal
of the auxiliary battery is grounded to the metal chassis of the vehicle.
The auxiliary battery is located in the trunk. It is concealed by a fabric
cover on the passenger side in the rear quarter panel well.
NOTE:
An under hood label shows the location of the HV battery (traction battery)
and 12 Volt auxiliary battery.
Battery Cover 12 Volt Auxiliary Battery Mounted in
Trunk
Battery Location Label

-14-
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. The inverter/converter creates 3-
phase AC to power the motor. Power cables are routed from the
inverter/converter to each high voltage motor (electric motor, electric generator,
and A/C compressor). The following systems are intended to help keep
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
breaching any orange high voltage power cable or high voltage
component.
Both positive and negative power cables are insulated from the metal
body. High voltage electricity flows through these cables and not through
the metal vehicle body. The metal vehicle body is safe to touch because it
is insulated from high voltage components.
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.
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)






A/C
Compressor
Electric
Generator
Electric
Moto
r
00
00
AC
3-Phase
Inverter/
Converter
Volt DC
Volt DC
HV Battery Assembly
12 Volt
Auxiliary
Battery
Hybrid Vehicle Computer
12 Volt
Auxiliary
Battery
Hybrid Vehicle Computer
HV Battery Assembly
Volt DC
Volt DC
A/C
Compressor
Electric
Generator
Electric
Moto
r
AC
3-Phase
Inverter/
Converter
244.8
244.8

-15-
SRS Airbags & Seat Belt Pretensioners
Standard Equipment
Electronic frontal impact sensors (2) are mounted in the engine
compartment as illustrated.
Front seat belt pretensioners are mounted near the base of the B-pillars .
A frontal dual stage driver airbag is mounted in the steering wheel hub.
A frontal dual stage passenger airbag is integrated into the dashboard
and deploys through the dashboard.
The SRS computer , which contains an impact sensor, is mounted on the
floor pan underneath the instrument panel, forward of the shift lever.
Front electronic side impact sensors (2) are mounted near the base of the B-
pillars .
Rear electronic side impact sensors (2) are mounted near the base of the C-
pillars .
Front seat side airbags are mounted in the seatbacks.
Side curtain airbags are mounted along the outer edge inside the roof
rails.
A driver knee airbag is mounted on the driver side lower portion of the
dash.
Front door electronic side impact sensors (2) are mounted inside the base of
the front doors .
Rear seat side airbags are mounted in the rear seat side garnish.
A passenger knee airbag is mounted in the lower portion of the
passenger side of the dash.
WARNING:
The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid breaching the SRS components.
Electronic Impact Sensors and Side Airbags
Standard Frontal Airbags, Seat Belt Pretensioners, Knee Airbags,
Side Curtain Airbags











Side Curtain Airbag
Inflators



-16-
SRS Airbags & Seat Belt Pretensioners (Continued)
Standard Equipment (Continued)
NOTE:
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.
The knee airbags deploy simultaneously with the frontal airbags and seat
belt pretensioners.
The Camry hybrid is equipped with a standard front passenger occupant
classification system that may prohibit the deployment of the front
passenger frontal airbag and seat belt pretensioner. If the passenger
occupant classification system prohibits deployment during an SRS event,
the passenger SRS will not re-arm nor deploy.
Electronic side impact sensors are installed in each front door to aid in side
collision detection accuracy.
SRS System Diagram
Frontal, Knee, Front and Rear Seatback Mounted Side, Side Curtain Airbags.
Driver Knee Airbag and Inflator
Front Airbag
Sensors
Passenger Frontal Airbag
Front Seat Side Airbag
Front Seat Side Airbag
Driver Knee Airbag
Side Airbag Sensor
Front Seat Belt Pretensioner
Side Curtain Airbag
Side Curtain Airbag
Rear Side
Airbag Sensor
Driver Frontal Airbag
Passenger Knee Airbag
Side Airbag Sensor Front Seat Belt Pretensioner
Rear Seat Side Airbag
Rear Seat Side Airbag
Front Door Side Airbag Sensor
Front Door Side Airbag Sensor

-17-
Emergency Response
On arrival, emergency responders should follow their standard
operating procedures for vehicle incidents. Emergencies involving the
Camry hybrid may be handled like other automobiles except as noted in
these guidelines for Extrication, Fire, Overhaul, Recovery, Spills, First
Aid, and Submersion.
WARNING:
Never assume the Camry hybrid is shut off simply because it is
silent.
Always observe the instrument cluster for the READY indicator
status to verify whether the vehicle is on or shut off. The vehicle is
shut off when the READY indicator is off.
Failure to shut off the vehicle before emergency response
procedures are performed may result in serious injury or death
from the unintentional deployment of the SRS or severe burns and
electric shock from the high voltage electrical system.
Extrication
Immobilize Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the Park position.
Disable Vehicle
Performing either of the following two procedures will shut the
vehicle off and disable the HV battery pack, SRS, and gasoline fuel
pump.
Chock Wheels Set Parking Brake
Shift Lever in Park
U.S.A. Canada