Toyota Camry, AHV40 Series Dismantling 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
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 ...............................................................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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