2009 Toyota Camry HV Service & Repair Manual

Last Modified: 5-5-2021 6.10:8.0.50 Doc ID: RM000000UYV05BX Model Year Start: 2009 Model: Camry HV Prod Date Range: [01/2008 - ] Title: INTRODUCTION: HOW TO USE THIS MANUAL: GENERAL INFORMATION; 2009 MY Camry HV [01/2008 - ] GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (b) Repair operations can be separated mainly in the following 3 processes: (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting (3) Final Inspection (c) The following procedures are omitted from this manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations (2) Clean all removed parts (3) Perform a visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the "Preparation" section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT:

There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Also has information such as specifications and warnings, which are written in boldface text (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference. 6. TERM DEFINITIONS CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. 7. INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Units from the metric system and the English systems are also provided. Example: Torque: 30 N·m {310 kgf·cm, 22ft·lbf}

Last Modified: 5-5-2021 6.10:8.0.50 Doc ID: RM000000UYW05PX Model Year Start: 2009 Model: Camry HV Prod Date Range: [01/2008 - ] Title: INTRODUCTION: IDENTIFICATION INFORMATION: VEHICLE IDENTIFICATION AND SERIAL NUMBERS; 2009 MY Camry HV [01/2008 - ] VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown in the illustration. A: Vehicle Identification Number B: Certification Label 2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine, and the transaxle serial number is stamped on the housing, as shown in the illustration. A: Engine Serial Number B: Transaxle Serial Number

Last Modified: 5-5-2021 6.10:8.0.50 Doc ID: RM000000UYX05YX Model Year Start: 2009 Model: Camry HV Prod Date Range: [01/2008 - ] Title: INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION; 2009 MY Camry HV [01/2008 - ] PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Attire Always wear a clean uniform. Hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safety operation When working in a pair or groups, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations Diagnose with a thorough understanding of proper procedures and of the reported problem.

Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. 6 Removed parts Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection if requested. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

ILLUSTRATION SYMBOL PART NAME ABBREVIATION FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during work, always replace the damaged clip with a new one. SHAPE (EXAMPLE) REMOVAL/INSTALLATION Remove clips with clip remover or pliers.

SHAPE (EXAMPLE) REMOVAL/INSTALLATION Remove fasteners with clip remover or screwdriver. Remove clips with wide scraper to prevent panel damage. Remove clips by pushing center pin through and prying out shell. Remove clips by unscrewing center pin and prying out shell. Remove clips by prying out pin and then prying out shell. (h) REMOVAL AND INSTALLATION OF VACUUM HOSES

(1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose. (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary. (i) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL (1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. Formula: T' = L2/(L1 + L2) * T T' Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. 2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE NOTICE:

The hybrid system contains a 244.8 V high-voltage system with a strong alkali solution of potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution. (a) Engineer must undergo special training to be able to perform high-voltage system inspection and servicing. (b) High-voltage cables are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components. (c) Before inspecting or servicing the high-voltage system, be sure to follow safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while your are servicing the vehicle. NOTICE: Before removing the service plug, confirm power switch off. Do not put the vehicle into the READY-on state after removing the service plug grip as the ECU may be damaged. (d) After removing the service plug, wait 10 minutes before touching any of the high-voltage connectors and terminals. HINT: 10 minutes are required to discharge the high-voltage condenser inside the inverter. (e) Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves. (f) When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit. (g) Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.

(h) After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape. (i) The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure. (j) Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high- voltage system is being inspected and/or repaired.

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2009 Toyota Camry HV Service & Repair Manual

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