Gasoline-Electric
Hybrid Synergy Drive
AVV50 Series
ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Toyota Camry
gasoline-electric hybrid vehicles. Camry hybrid dismantling procedures are similar to other non-hybrid
Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize
and understand the high voltage electrical system features and specifications of the Toyota Camry hybrid,
as they may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional 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 NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
• Toyota Camry hybrid identification.
• Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle Camry hybrid-electric
vehicles as safely as the dismantling of a conventional non-hybrid automobile.
© 2011 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 Hybrid.......................................................................................................................... 1
Camry Hybrid Identification....................................................................................................................2
Exterior .........................................................................................................................................................3
Camry Hybrid 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
HV Battery Pack............................................................................................................................................9
Components Powered by the HV Battery Pack.............................................................................................9
HV Battery Pack Recycling.........................................................................................................................10
Auxiliary Battery..........................................................................................................................................10
High V oltage Safety.................................................................................................................................11
High Voltage Safety System........................................................................................................................11
Service Plug Grip........................................................................................................................................12
Precaution to be observed when dismantling the vehicle.....................................................................13
Necessary Items.........................................................................................................................................13
Spills..........................................................................................................................................................14
Dismantling the vehicle...........................................................................................................................15
Removal of HV battery...........................................................................................................................18
HV Battery Caution Label ...........................................................................................................................30
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
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.
n During light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
o During normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery pack.
p During full acceleration, such as climbing a hill, both the gasoline engine and the electric
motor power the vehicle.
q During deceleration, such as when braking, the vehicle regenerates the kinetic energy
from the wheels to produce electricity that recharges the battery pack.
r While the vehicle is stopped, the gasoline engine and electric motor are off, however the
vehicle remains on and operational.
1
r Stopping
n Starting
o Normal Driving
p
Acceleration
q
Deceleration
Electricity Electricity and gasoline
Charging batteries
Electricity and gasoline
(additional electricity
extracted from batteries)
Engine automaticall
y
stopped
Camry Hybrid Identification
In appearance, the 2012 model year 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, right side floor and on the left side B pillar.
Example VIN:
4T1BD1FK0CU001001 (U.S.A., Canada and South Korea)
JTNBD4FK0CU001001 (General)
A Camry hybrid is identified by the first 8 alphanumeric characters 4T1BD1FK or JTNBD4FK.
Left Side Windshield Cowl, Right Side Floor and Left Side B Pillar
2
Camry Hybrid Identification (Continued)
Exterior
and logos on the luggage compartment door. n
o logo on each front fender.
Exterior Left Side View
Exterior Front View
Exterior Rear View
Exterior Rear and Left Side View
General
U.S.A., Canada
and South Korea
o
o
General
U.S.A., Canada and South Korea
U.S.A., Canada and South Korea
General
n
n
n
n
General
U.S.A., Canada and South Korea
n
o o n n n
3
Camry Hybrid Identification (Continued)
Interior
p Instrument cluster (speedometer, READY light, shift state indicators, warning lights) located in the
center of the dash and near the base of the windshield.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.
Interior View of Front Door Sill
Instrument Cluster View
U.S.A., Canada and South Korea
General
p
p p
READY Indicator
READY Indicator
4
Camry Hybrid Identification (Continued)
Engine Compartment
q 2.5-liter aluminum alloy gasoline engine.
r Logo on the plastic engine cover.
s Orange colored high voltage power cables.
Engine Compartment View
Power Cables
r
q
s
5
6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt n
Auxiliary Battery
Right Side of
Trunk
A lead-acid battery that supplies power to the low voltage
devices.
Hybrid o Vehicle
(HV) Battery Pack
Trunk, Mounted to
Cross Member
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 p 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 q
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 r
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.
Electrics
Motor
Engine
Compartment
3-phase high voltage AC permanent magnet electric motor
contained in the front transaxle. It is used to power the
front wheels.
Electric t
Generator
Engine
Compartment
3-phase high voltage A C generator that is contained in the
transaxle and recharges the HV battery pack.
A/C Compressor
(with Inverter) u
Engine
Compartment
3-phase high voltage AC electrically driven motor
compressor.
Fuel Tank and Fuel
Line v
Undercarriage and
Center
The fuel tank provides gasoline via a fuel line to the
engine. The fuel line is routed under the center of
vehicle.
*Numbers in the component column apply to the illustrations on the following page.
Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine:
155 hp (116 kW), 2.5-liter Aluminum Alloy Engine (U.S.A., Canada, South Korea)
158 hp (118 kW), 2.5-liter Aluminum Alloy Engine (General)
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 W eight:
3,483 lbs/1,580 kg
Fuel T ank:
17.2 gals/65.0 liters
Frame Material: Steel Unibody
Body Material:
Steel Panel
Seating Capacity: 5 standard
n
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p
q
u
ts
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