Foreword CAMRY This guide was developed to educate and assist dismantlers in the safe handling of Toyota Camry CAMRY gasoline-electric hybrid vehicles

Transcription

1 Gasoline-Electric Hybrid Synergy Drive Revised AHV4# Series i

2 Foreword CAMRY This guide was developed to educate and assist dismantlers in the safe handling of Toyota Camry CAMRY gasoline-electric hybrid vehicles. Camry Hybrid dismantling procedures are similar to other CAMRY 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 electric motor, generator, A/C compressor, and inverter/converter. All other automotive electrical devices such as the headlights, 12 V power steering, CAMRY 245 V (NiMH) (HV) 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 CAMRY identification. Major hybrid component locations and descriptions. By following the information in this guide, dismantlers will be able to handle the CAMRY CAMRY hybrid-electric vehicle as safely as the dismantling of a conventional gasoline engine automobile 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 ii

3 Table of Contents About CAMRY... the 1 CAMRYIdentification... 2 Exterior CAMRY Identification... (Continued)... 5 Interior Engine Compartment Hybrid... Component Locations & Descriptions 7... Specifications...88 Hybrid... Synergy Drive Operation 9... Vehicle Operation...9 Hybrid Vehicle (HV)... Battery Pack and Auxiliary Battery Components... to Which High Voltage is Applied...10 HV... Battery Pack Recycling 11 High... Voltage Safety 12 Service... Plug...13 Precaution... to be observed when dismantling the vehicle Necessary... items Spillage Dismantling a vehicle 16 HV Removal... of HV battery HV... battery removal...19 HV... Battery Caution Label...31 iii

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5 About CAMRY the CAMRY CAMRY The CAMRY hybrid sedan joins PRIUS the PRIUS HIGHLANDER and 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 (HV) Hybrid Vehicle (HV) battery pack for the electric motor. The result of combining these two power sources is improved fuel economy and reduced CAMRY 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 CAMRY 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. 1

6 CAMRY Identification CAMRY In appearance, the CAMRY hybrid is nearly identical to the conventional, CAMRY CAMRY non-hybrid Toyota CAMRY. The CAMRY 4 hybrid is a 4-door sedan. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric (VIN) 17 character 17 Vehicle Identification Number (VIN) is provided in the front windshield cowl or right side floor and left side door pillar. VIN Example VIN: JTNBB46S######### (2007 to 2009 models for 2007 U.S.A. and 2009 Canada) 4T1BB46S######### (2007 to 2009 models for 2007 U.S.A. and 2009 Canada) JTNBB3EK######### (2010 model for U.S.A., Canada and 2010 South Korea) 4T1BB3EK######### (2010 model for U.S.A. and 2010 Canada) LVGBB40K######### (for China) 6T153FK4######### (for Australia and New Zealand) MR053FK4######### (for Thailand) CAMRY A CAMRY hybrid is identified by 6 JTNBB44T1BB4JTNBB3 the first 6 alphanumeric characters JTNBB4, 4T1BB4, JTNBB3, 4T1BB3LVGBB46T153F 4T1BB3, LVGBB4, and MR053FK For U.S.A., Canada and South Korea: Driver Side Windshield and Driver Side B B Pillar Others: Front Passenger Door Pillar and Under Front Right Side Seat 2

7 Exterior (for U.S.A., Canada, South Korea, Australia and New Zealand) CAMRY logo on the trunk door. HYBRID SYNERGY DRIVElogo on the trunk lid. HYBRID logo on each front fender. Gasoline fuel filler door located on the driver side rear quarter panel. HYBRID SYNERGY DRIVE CAMRY Exterior Rear and Passenger Side View Exterior Driver Side View Exterior Front View 3

8 Exterior (for China and Thailand) HYBRID logo on the trunk door. HYBRID SYNERGY DRIVE logo on the trunk lid. HYBRID logo on each front door. Gasoline fuel filler door located on the driver side rear quarter panel. HYBRID SYNERGY DRIVE HYBRID Exterior Rear and Passenger Side View Exterior Driver Side View Exterior Front View 4

9 CAMRY Identification (Continued) Interior The instrument cluster (speedometer, fuel gauge, and warning lights) located in the dash behind CAMRY 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) (mpg) or 100little km per 100 km consumption is used. A multi-information display showing energy flow is provided in the center of the speedometer. Interior View Instrument Cluster View 5

10 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

11 Hybrid Component Locations & Descriptions Component Location Description 12Volts V Auxiliary Battery Hybrid Vehicle (HV) (HV) Battery Pack Power Cables Inverter/ / Converter Gasoline Engine Electric Generator Electric Motor A/C Compressor 12Volts V DC- DC DC-DC Converter Fuel Tank and Fuel Line Trunk A lead-acid battery that supplies power to the low voltage devices. Trunk Area, Mounted Volts V Nickel (NiMH) Metal Hydride (NiMH) 34 battery pack 7.2 consisting V to Cross Member and of 34 low voltage (7.2 Volts) modules connected in series. behind Rear Seat Under Carriage and Orange colored HV power / supply cables carry high voltage Direct Engine Compartment Current (DC) between (DC)/ the HV battery pack, inverter/converter, and 3 (AC) A/C compressor. These cables also carry 3-phase Alternating Current (AC) between the inverter/converter, electrical motor, and generator. Engine Compartment Boosts HV and inverts the high voltage electricity 3 from the HV battery pack / to 3-phase AC electricity / that drives the electric motor. The HV inverter/converter also converts AC electricity from the electric generator and electric motor (regenerative braking) to DC that recharges the HV battery pack. Engine Compartment Provides two functions: 1 1) Powers vehicle. 2 2) Powers generator HV to recharge the HV battery pack. The engine is started and stopped under control of the vehicle computer. Transaxle 3-phase 3 high voltage AC generator that is HV contained in the transaxle and recharges the HV battery pack. Transaxle 3-phase 3 high voltage AC permanent magnet electric motor contained in the transaxle. Used to power the front wheels. Engine Compartment 3-phase 3 high voltage AC electrically driven motor compressor. Inside HV HV Battery Converts HV Volts DC from V the HV battery 12 pack V to 12 Volts DC Pack Assembly in for low voltage vehicle power. Trunk Undercarriage, The fuel tank provides gasoline via single fuel line to the engine. Driver Side The fuel line is routed along the driver side under the floor pan. 7

12 Specifications Gasoline 147 Engine: 147 hp (110 hp (110 KW)2.4 KW), 2.4-liter L Aluminum Alloy Engine Electric 141 Motor: 141 hp (105 hp (105 KW) KW), Permanent Magnet Motor Transmission: Automatic Only HV V NiMH HV 3,638 Battery: lbs / Volts 1,650 Sealed kg NiMH Battery Pack Curb 17.2 Weight: 3,638 gal / 65 lbs L/ 1,650 kg Fuel Tank: 17.2 gals / 65 liters Frame Material: Steel Unibody Body Material: Steel Panels Power Cable 8

13 Hybrid Synergy Drive Operation Once the READY READY indicator is illuminated in the instrument cluster, the vehicle may be driven. READY However, the gasoline engine does not idle like a typical automobile and will start and stop READY 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 CAMRY READY 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 READY is off. Always look for READY the READY indicator status. The vehicle is shut off when the READY indicator is off. The vehicle may be powered by: The electric motor only The gasoline engine only A combination of both the electric motor and the gasoline 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

14 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery CAMRY The CAMRY hybrid contains a high voltage, Hybrid (HV) Vehicle (HV) battery pack that contains (NiMH) sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack The HV HV battery pack is enclosed in a metal case and is securely mounted in the trunk area behind the rear seat. The metal case is isolated from high voltage and concealed by fabric covers. The HV HV battery pack 34 consists of 34 low (7.2 voltage V) NiMH (7.2 Volts) NiMH battery modules connected V in series to produce NiMH approximately Volts. Each NiMH battery module is non-spillable and sealed in a plastic case. The NiMH 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. Battery pack voltage HV Battery Pack V Number of NiMH battery modules in the pack 34 NiMH battery module voltage NiMHbattery module dimensions NiMH module weight NiMHbattery Pack dimensions NiMHbattery Pack weight 7.2 V 5 x 1 x 11 in. (118 x 20 x 276 mm) 2.3 lbs (1.0 kg) 8 x 34 x 19 in. (190 x 850 x 495 mm) lbs (52 kg) Components to Which High Voltage is Applied Electric Motor Power Cables Inverter/Converter / DC-DC Converter A/C Compressor Electric Generator 10

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16 High Voltage Safety HV // HV The HV battery pack powers the high voltage electrical system with DC electricity. Positive V 650 V 3 and negative orange colored 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 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 HV provides short circuit protection in the HV battery pack. Positive HV and negative high voltage power cables 12 Vconnected to the HV battery pack are controlled by 12 Volt HV 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 10 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 CHECK HYBRID SYSTEM will illuminate the master warning light in the instrument cluster and indicate CHECK HYBRID SYSTEM on the multi-information display. The HV battery pack SRS relays HV will automatically open to stop the electrical flow in a collision sufficient to activate the SRS. 12

17 Service Plug The high-voltage circuit is cut by removing service 16 plug (See page 16). 0 Volts V 3 AC 3-Phase A/C Compressor Volts DC HV Battery Electric Motor Generator Inverter/ / Converter DC/DC Converter VVolts DC 12 V12 Volts Battery Hybrid Vehicle Computer High Voltage Safety System - READY Vehicle Shut Off - (READY-OFF) A/C Compressor HV HV Battery 650 Volts V 3 AC 3-Phase VVolts DC Electric Motor Generator / Inverter/ Converter DC/DC DC/DC Converter VVolts DC 12 V12 Volts Battery Hybrid Vehicle Computer High Voltage Safety System - READY Vehicle On and Operational (READY-ON) - 13

18 Precaution to be observed when dismantling the vehicle WARNING: The high voltage system may remain powered for up to 10 minutes 10 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. 14

19 Spillage The HV CAMRY contains the NiMH same CAMRY common automotive fluids used in other non-hybrid Toyota NiMH vehicles, with the exception of NiMH electrolyte used in (ph the HV 13.5) 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 neutralize a lead-acid battery electrolyte spill, a dilute boric acid NiMH solution or vinegar can be used to neutralize a NiMH battery electrolyte spill. In an emergency, Toyota Material Safety Data Sheets (MSDS) are available by contacting: (PPE) Handle NiMH electrolyte Spills NiMH 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. Neutralize NiMH NiMH Electrolyte Use a boric acid solution or vinegar. - Boric acid solution 800 g grams L 5.5 boric acid oz. to 20 1 liters water gal or 5.5 ounces boric acid to 1 gallon of water 15

20 Dismantling a vehicle WARNING: The high voltage system may remain powered for up to 10 minutes 10 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 16

21 3. Carry the removed service plug in your pocket to prevent other staff from reinstalling it while you are dismantling the vehicle. 4. Make other staff aware that a high-voltage system is being 18 dismantled by using the following sign: CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION (see page 18). 5. If the service plug cannot be removed due to damage to the rear IGCT portion of the vehicle, remove the IGCT No. 2 fuse. Caution: This operation shuts HV off the HV system. Be HVsure to wear insulated gloves because high voltage is not shut off inside the HV battery. When it is possible to remove the service plug, remove it and continue the procedure. Fuse Box IGCT 2 IGCT No. 2 Fuse 6. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape. Before touching a bare high-voltage terminal, wear insulated gloves. 7. Check HV the HV battery and nearby area for leakage. If you find any liquid, it may be strong alkaline electrolyte. Wear rubber gloves and goggles and neutralize the liquid using a saturated boric acid solution or vinegar. Then wipe up the liquid using waste rags etc. a) If the electrolyte adheres to your skin, wash the skin immediately using a saturated boric acid solution or a large amount of water. If the electrolyte adheres to any article of clothing, take the clothing off immediately. b) If the electrolyte comes into contact with your eye(s), call out loudly for help. Do not rub your eye(s). Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 8. Remove HV the parts by following the procedures which are similar to the Toyota HV vehicles with exception of HV battery. As for the removal of HV battery, refer to the following pages. 17

22 HV 18

23 Removal HV of HV battery HV battery removal WARNING: Be sure to wear insulated gloves when handling high-voltage parts. Even if the vehicle is shut off and the relay is off, be sure to remove the service plug grip before performing any steps. Power remains in the high voltage electrical HV system for 10 minutes even after the HV battery pack is shut off because the circuit has a condenser. Make sure that the tester reading is 0 V before touching 0 any Vhigh-voltage terminals which are not insulated. 1. Disconnect the cable form the auxiliary battery negative terminal. 2. Remove the service plug grip. a) Remove the battery service hole cover. b) Wear insulated gloves and raise the service plug grip as shown in the illustration. Then, remove the HVbattery Service Plug Grip service plug grip. c) Apply electrical tape to the socket of the service plug grip to insulate it. Battery service hole cover 19

24 3. Remove the luggage LH compartment rear trim cover LH. Remove the luggage compartment floor mat. Remove the spare wheel cover clamp. Remove the spare wheel cover assembly. Remove the No. 1 1 luggage compartment trim hooks. Remove the rear floor finish plate. Remove the luggage compartment rear trim cover. Remove the luggage LH compartment inner trim cover LH. 20

25 4. Remove the rear side seatback LH assemblies LH, center and RH. RH Remove the rear seat headrest assemblies. Remove the rear seat cushion assembly. Remove the 4 bolts on the 4 rear side of the seatback. Remove the separate type LH rear seatbacks RH LH and RH. Remove 2 the 2 bolts and rear side seatback assemblies. 5. Remove the rear door LH scuff RH plates LH and RH. 6. Remove the rear door opening LH trim RH weatherstrips LH and RH. 21

26 7. Disconnect the rear seat inner with center belt assembly LH LH. 8. Remove the rear seat inner with center belt assembly RHRH. 9. Remove the roof side LH inner RH garnishes LH and RH. a) Disengage 5 the 5 clips 2 and 2 claws, and remove the roof side inner garnish. 10. Remove the rear seat outer belt LH assemblies RHLH and RH. 22

27 11. Using a screwdriver, 4 disengage the 4 claws and remove the rear seat shoulder belt cover. 12. Using a screwdriver, 4 disengage the 4 claws and remove the rear seat shoulder belt hole cover. 13. Remove the package tray trim panel assembly. a) Disconnect the connector. b) Disengage 4 the 4 clips 5 and 5 claws. c) Pass 3 the 3 rear seat belt floor anchors through the package tray trim panel assembly, then remove the package tray trim panel assembly. 14. Remove 3 the 3 clips and front luggage compartment trim cover. 23

28 15. Remove the room LH partition RHboards LH and RH. a) Remove 4 the 4 clips and room partition LH board LH. b) Remove 4 the 4 clips and room partition RH board RH. 16. Remove 1 the HV No. 1 HV battery intake duct. 17. Remove 2 the 2 bolts, clip, and 2 No. HV2 HV battery intake duct. 24

29 18. Remove the battery cooling blower assembly. a) Remove the bolt from the battery cooling blower assembly. b) Disconnect the connector from the battery cooling blower assembly. c) Remove the battery cooling blower assembly as shown in the illustration. 19. Remove the clip 5 and HVNo. 5 HV battery intake duct. 20. Remove 3 the HV No. 3 HV battery intake duct. 25

30 21. Remove 2 the 2 clips 4 and HV No. 4 HV battery intake duct. 22. Remove 2 the 2 clips nut 2 and No. HV 2 HV battery exhaust duct. 23. Remove the wire harness clamp bracket. a) Using the service plug grip, release the interlock button. b) Remove the bolt, nut, and wire harness clamp bracket. c) Disconnect 2 the 2 wire harness clamps. Service Plug grip Interlock Button 26

31 24. Remove the upper battery carrier sub-assembly. a) Remove 2 the 2 nuts and ground cable. b) Remove 3 the 3 nuts, bolt, and upper battery carrier sub-assembly. 25. Disconnect the frame wire. a) Remove the battery shield contact. b) Remove 2 the 2 nuts and disconnect the frame wire (High Voltage cable). Caution: Insulate the terminals that the high voltage cable was connected to using something such as insulating tape. 27

32 26. Install the spare wheel cover assembly. 27. Install the spare wheel cover clamp. 28. Install the luggage compartment floor mat. 29. Remove HV the HV battery. a) Disconnect 1 the wire harness clamp from the No. 1 battery cover. b) Release 2 the 2 claws and remove the terminal block cover. Caution: Make sure that the negative terminal is disconnected from the auxiliary battery before performing the next step. c) Remove AMD the nut and disconnect the frame wire (AMD cable). d) Disconnect the battery pack wire connector. 28

33 e) Remove the grommet and battery room ventilation hose. f) Remove HV the 4 bolts from 4 the HV battery. g) Remove HV the 2 bolts from 2 the HV battery. h) Prepare a piece 750 mm of cardboard (29.53 in.) of X mm mm (19.69 (29.53 in.) in.) X 500 mm (19.69 in.) or larger. i) Using a tire lever to hold HV up the HV battery, insert the cardboard until it cannot be inserted any further. Hold Up Insert Cardboard 750 mm (29.53 in.) 500 mm (19.69 in.) or Larger 29

34 j) Pull the HV battery HV together with the cardboard toward the rear of the vehicle. Pull k) Using HV an engine sling device, 45 remove the HV battery HV while tilting the HV battery 45 at the rear end. Cardboard 30. The HV HV battery pack is recyclable. Contact HV your Toyota distributor which is found on the HV Battery Caution Label or contact the nearest Toyota Dealer. (See the next page) Caution: After HV removing the HV battery, do not connect HV the service plug to the HV battery. 30

35 HV Battery Caution Label Hint: The label content may change due to regulatory revisions, etc to models for 2009 U.S.A model for 2010 U.S.A to 2009 models 2007 for 2009 CANADA 31

36 model for 2010 CANADA 5. For AUSTRALIA, NEW ZEALAND, SOUTH KOREA and THAILAND 6. For CHINA 32