Toyota Camry Hybrid AHV40 Manual

page of 430

/ 430
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

To assist you in your service activities, this manual explains the main characteristics of the new Camry Hybrid

model in particular providing a technical explanation of the construction and operation of new mechanism and

new technology used.

This manual is divided into 3 sections.

1. New Model Outline - Explanation of the product to give a general understanding of its features.

2. Technical Description - Technical explanation of the construction and operation of each new system and

3. Appendix - Major technical specifications of the vehicle.

CAUTION, NOTICE, REFERENCE and NOTE are used in the following ways:

CAUTION

NOTICE

REFERENCE

NOTE

For detailed service specifications and repair procedures, refer to the following Repair Manuals:

D 2007 CAMRY Hybrid Vehicle Repair Manual

D 2007 CAMRY Hybrid Vehicle Electrical Wiring Diagram

All information contained herein is the most up-to-date at the time of publication. We reserve the right to make

changes without prior notice.

2006

TOYOTA MOTOR CORPORATION

duced or copied, in whole or in part, without the

written permission of Toyota Motor Corporation.

First Printing: Mar. 06, 2006 01-060306-00

FOREWORD

Applicable models: AHV40

component.

A potentially hazardous situation which could result in injury if instructions are

ignored.

Damage to the vehicle or components may occur if instructions are ignored.

Explains the theory behind mechanisms and techniques.

Notes or comments not included under the above 3 titles.

Manual Name

Pub. No.

RM02H0U

EM02H0U

Table of Contents

Need help?

Do you have a question about the Camry Hybrid AHV40 and is the answer not in the manual?

Questions and answers

Summary of Contents for Toyota Camry Hybrid AHV40

Page 1 All information contained herein is the most up-to-date at the time of publication. We reserve the right to make changes without prior notice. 2006 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Mar. 06, 2006 01-060306-00...
Page 2 JDESCRIPTION 1. General Under the “Hybrid Synergy Drive” concept, the ’07 Camry Hybrid model uses THS II (Toyota Hybrid System II). This system optimally effects cooperative control of a 2AZ-FXE engine and a high-speed, high-output MG2 through a hybrid transaxle that provides excellent transmission performance.
Page 3 TH-3 THS II (TOYOTA HYBRID SYSTEM II) JFEATURES OF THS II 1. General D The THS II offers the following representative features: - Uses a variable-voltage system in which a boost converter boosts the operating voltage of the system to a maximum voltage of DC 650 V and an inverter converts the direct current into an alternating current, which supplies the system voltage to MG1 and MG2.
Page 4 TH-4 THS II (TOYOTA HYBRID SYSTEM II) 3. Clutch-Less System A clutch-less system is used to mechanically link the front wheels and MG2 via gears. To disengage the motive force in the neutral position, the shift position sensor outputs an N position signal to turn OFF all the power transistors in the inverter (which controls MG1 and MG2).
Page 5 TH-5 THS II (TOYOTA HYBRID SYSTEM II) 5. Link-Less The ETCS-i (Electronic Throttle Control System-intelligent) is used. This is a link-less system that does not use an accelerator cable. Instead, it uses an accelerator pedal position sensor and a throttle position sensor to detect the accelerator pedal position and the throttle position.
Page 6 TH-6 THS II (TOYOTA HYBRID SYSTEM II) 7. Basic Operation This system generates a motive force in combination with the engine, MG1 and MG2 in accordance with the driving conditions. Representative examples of the various combinations are described below. Starting (Drive by MG2)
Page 7 : CAN (CAN No.1 Bus) Inverter Assembly Circuit Breaker : Mechanical Power Path Sensors : Hydraulic Power Path Inverter : Power Cable Shift Position (High-voltage, High-amperage) Sensor : Electrical Signal Boost MG ECU Accelerator Converter Pedal Position Sensor Electrical Inverter Compressor DC/DC Inverter...
Page 8 TH-8 THS II (TOYOTA HYBRID SYSTEM II) JLAYOUT OF MAIN COMPONENTS Steering Angle A/C ECU Sensor Combination Meter Skid Control Accelerator Pedal Position Sensor Stop Light Switch Yaw Rate and DLC3 Deceleration Rate Sensor Airbag Sensor Auxiliary Assembly Battery THS ECU...
Page 9 TH-9 THS II (TOYOTA HYBRID SYSTEM II) JFUNCTION OF MAIN COMPONENTS Item Outline D MG1, which is driven by the engine, generates high-voltage electricity in order to operate MG2 or charge the HV battery. Also, it functions as a starter to start the engine.
Page 10 TH-10 THS II (TOYOTA HYBRID SYSTEM II) Item Outline D During braking, it calculates the regenerative brake force that is required for control and transmits it to the THS ECU. D Calculates the motive force that is required for control...
Page 11 TH-11 THS II (TOYOTA HYBRID SYSTEM II) JSYSTEM OPERATION 1. General D The THS II uses two sources of motive force, the engine and MG2, and uses MG1 as a generator. The system optimally combines these forces in accordance with the various driving conditions.
Page 12 TH-12 THS II (TOYOTA HYBRID SYSTEM II) 2. How to Read a Nomographic Chart D The nomographic chart below gives a visual representation of the planetary gear’s rotational direction, rotational speed, and torque balance. D In the nomographic chart, a straight line is used to represent the relationship between the rotational speeds of the 3 gears in the power split planetary gear unit.
Page 13 TH-13 THS II (TOYOTA HYBRID SYSTEM II) 3. Starting with MG2/(B) D When the vehicle is started off, the vehicle operates powered only by the MG2. : Electrical Path : Mechanical Power Path Engine Compound Hybrid Gear Unit Transaxle Inverter...
Page 14 TH-14 THS II (TOYOTA HYBRID SYSTEM II) 4. Running with MG2 and Engine/(C) D If the required drive torque increases when running with MG2 only, MG1 is activated to start the engine. In addition, if any one of the items monitored by the THS ECU such as the SOC condition, the battery temperature, the engine coolant temperature or the electrical load condition deviates from the specified level, MG1 is activated to start the engine.
Page 15 TH-15 THS II (TOYOTA HYBRID SYSTEM II) 5. During Low Load and Constant-Speed Cruising/(D) D When the vehicle is running under low load and constant-speed cruising conditions, the motive force of the engine is transmitted by the planetary gears. Some of this motive force is output directly, and the remaining motive force is used for generating electricity through MG1.
Page 16 TH-16 THS II (TOYOTA HYBRID SYSTEM II) 6. During Full Throttle Acceleration/(E) D When the vehicle driving condition changes from low load cruising to full-throttle acceleration, the system supplements the motive force of MG2 with electrical power from the HV battery.
Page 17 TH-17 THS II (TOYOTA HYBRID SYSTEM II) 7. During Deceleration Driving/(F) Deceleration in “D” Range D While the vehicle is decelerated with the shift lever in the D position, the engine is turned OFF and the motive force changes to zero. At this time, the wheels drive MG2, causing MG2 to operate as a generator, charging the HV batteries.
Page 18 TH-18 THS II (TOYOTA HYBRID SYSTEM II) 8. During Reverse Driving/(G) D When the vehicle is being driven in reverse, the required power is supplied by MG2. At this time, MG2 rotates in the opposite direction, the engine remains stopped, and MG1 rotates in the normal direction without generating any electricity.
Page 19 TH-19 THS II (TOYOTA HYBRID SYSTEM II) JCONSTRUCTION OF MAIN COMPONENTS 1. MG1 and MG2 General D Serving as the source of supplemental motive force that provides power assistance to the engine as needed, the electric motor helps the vehicle achieve excellent dynamic performance, including smooth start-offs and acceleration.
Page 20 TH-20 THS II (TOYOTA HYBRID SYSTEM II) " MG1 Specifications Type Permanent Magnet Motor Function Generate, Engine Starter Maximum System Voltage* DC 650 V Cooling System Water-cooled " MG2 Specifications Type Permanent Magnet Motor Function Generate, Drive Front Wheels Maximum System Voltage*...
Page 21 TH-21 THS II (TOYOTA HYBRID SYSTEM II) Permanent Magnet Motor (for MG1 and MG2) D When a three-phase alternating current is passed through the three-phase windings of the stator coil, a rotational magnetic field is created in the electric motor. By controlling this rotating magnetic field according to the rotor’s rotational position and speed, the permanent magnets that are provided in the...
Page 22 TH-22 THS II (TOYOTA HYBRID SYSTEM II) Speed Sensor/Resolver (for MG1 and MG2) D This is an extremely reliable and compact sensor that precisely detects the magnetic pole position, which is indispensable for ensuring the efficient control of MG1 and MG2.
Page 23 TH-23 THS II (TOYOTA HYBRID SYSTEM II) D Because an alternating current flows from this resolver to the excitation coil at a constant frequency, a constant frequency is output to the coils S and C, regardless of the rotor speed. The rotor is oval, and the distance of the gap between the stator and the rotor varies with the rotation of the rotor.
Page 24 TH-24 THS II (TOYOTA HYBRID SYSTEM II) 2. Inverter Assembly General D The inverter converts the high-voltage direct current of the HV battery into three-phase alternating current for driving MG1 and MG2. D The activation of the power transistors is controlled by the THS ECU, via the MG ECU. In addition, the inverter transmits information that is needed for current control, such as the output amperage or voltage, to the THS ECU via the MG ECU.
Page 25 TH-25 THS II (TOYOTA HYBRID SYSTEM II) " System Diagram IPM for MG1 Power Current Current & MG2 Transistor Sensor Sensor Inverter Boost IPM Reactor Boost Converter Inverter Assembly HV battery DC/DC A/C Inverter Converter 02HTH24Y...
Page 26 TH-26 THS II (TOYOTA HYBRID SYSTEM II) Boost Converter D This boost converter boosts the nominal voltage of DC 244.8 V that is output by the HV battery to the maximum voltage of DC 650 V. The converter consists of the boost IPM (Intelligent Power Module) with a built-in IGBT (Insulated Gate Bipolar Transistor) which performs the switching control, and the reactor which stores energy.
Page 27 TH-27 THS II (TOYOTA HYBRID SYSTEM II) MG (Motor Generator) ECU D The MG ECU is provided in the inverter assembly. In accordance with the signals received from the THS ECU, the MG ECU controls the inverter and boost converter in order to drive MG1 or MG2 or cause them to generate electricity.
Page 28 TH-28 THS II (TOYOTA HYBRID SYSTEM II) 4. HV Battery General D The ’07 Camry Hybrid model uses sealed nickel metal hydride (Ni-MH) HV batteries. The HV batteries have a high power density, are lightweight and offer longevity to match the characteristics of the THS II.
Page 29 TH-29 THS II (TOYOTA HYBRID SYSTEM II) " Battery Specifications Type Sealed Nickel Metal Hydride Battery Cell Quantity 204 cells (6 cells x 34 Modules) Cell Type Nickel Plated Metal Container Nominal Voltage 244.8 V Layout of Main Components HV Battery...
Page 30 TH-30 THS II (TOYOTA HYBRID SYSTEM II) DC/DC Converter The power source for auxiliary equipment of the vehicle such as the lights, audio system, and the air conditioning system (except electric inverter compressor), as well as the ECUs, is based on a DC 12 V system.
Page 31 TH-31 THS II (TOYOTA HYBRID SYSTEM II) Service Plug By removing the service plug before performing any inspection or service, the high-voltage circuit is shut off at the intermediate position of the HV battery, thus ensuring safety during service. The service plug assembly contains a reed switch for interlock. Lifting the clip lock up turns OFF the lead switch, which shuts off the SMR.
Page 32 TH-32 THS II (TOYOTA HYBRID SYSTEM II) HV Battery and DC/DC Converter Cooling System 1) HV Battery Cooling System D A dedicated cooling system is used to ensure that the HV battery performs properly, despite it generating significant heat during the repetitive charge and discharge cycles.
Page 33 TH-33 THS II (TOYOTA HYBRID SYSTEM II) 2) DC/DC Converter Cooling System As with as the HV battery cooling system, the DC/DC converter cooling system uses a dedicated cooling fan to cool the converter. Air from inside the cabin is introduced through the intake duct located on the rear package tray trim.
Page 34 TH-34 THS II (TOYOTA HYBRID SYSTEM II) 5. Accelerator Pedal Position Sensor The magnetic yoke that is mounted at the base of the accelerator pedal arm rotates around the Hall IC in accordance with the amount of effort that is applied to the accelerator pedal. The Hall IC converts the changes in the magnetic flux that occur at that time into electrical signals, and outputs them in the form of accelerator pedal effort to the THS ECU.
Page 35 TH-35 THS II (TOYOTA HYBRID SYSTEM II) 6. Power Cable The power cable is a high-voltage, high-amperage cable that connects the HV battery module with the inverter, the inverter with MG1 and MG2, and the inverter with the electric inverter compressor. The power cable starts at the connector of the junction block of the HV battery, which is located behind the rear seat.
Page 36 TH-36 THS II (TOYOTA HYBRID SYSTEM II) JTHS II CONTROL SYSTEM 1. General The THS II control system contains the following components. Item Outline D The THS ECU calculates the target motive force based on the shift position, the degree to which the accelerator pedal is depressed, and the vehicle speed.
Page 37 TH-37 THS II (TOYOTA HYBRID SYSTEM II) Item Outline D The inverter converts the direct current from the HV battery into an alternating current for MG1 and MG2, or vice versa, in accordance with the signals provided by the THS ECU via the MG ECU. In addition, the inverter supplies the alternating current from the MG1 power to MG2.
Page 38 TH-38 THS II (TOYOTA HYBRID SYSTEM II) 2. Construction The configuration of the THS II control system in the ’07 Camry Hybrid model is shown in the following chart. : CAN (CAN No.1 Bus) : Serial Communication METER ECU SKID CONTROL ECU...
Page 39 TH-39 THS II (TOYOTA HYBRID SYSTEM II) WATER PUMP DRIVER INTERLOCK SWITCH (for INVERTER) (for SERVICE PLUG) FCTL COOLING FAN RELAY COOLING FAN (for HV BATTERY) LST1 LST2 BTH+ BATTERY SMART UNIT BTH- COMBINATION METER SPD1 No.1 Injector No.2 Injector No.3 Injector...
Page 40 TH-40 THS II (TOYOTA HYBRID SYSTEM II) 3. THS ECU Control General D The THS ECU detects the amount of effort applied to the accelerator pedal in accordance with the signals provided by the accelerator pedal position sensor. The THS ECU receives signals from the speed sensor (resolver) in the MG1 and MG2, and detects the shift position signal from the shift position sensor.
Page 41 TH-41 THS II (TOYOTA HYBRID SYSTEM II) " System Diagram THS ECU Temperature Signal Motor-Speed Signal Accelerator Pedal Inverter Position Sensor Engine Control Shift Position Boost Converter Sensor MG1 and MG2 Serial Control Communication DC-DC Converter Battery Smart Unit D Voltage...
Page 42 TH-42 THS II (TOYOTA HYBRID SYSTEM II) System Monitoring Control D The THS ECU constantly monitors the SOC (state of charge) of the HV battery. When the SOC is below the lower level, the THS ECU increases the power output of the engine to operate MG1, which charges the HV battery.
Page 43 TH-43 THS II (TOYOTA HYBRID SYSTEM II) SMR (System Main Relay) Control 1) General The SMR is a relay that connects and disconnects the power source of the high-voltage circuit upon receiving a command from the THS ECU. A total of three relays are used: one (SMRB) at the positive side, and two (SMRP and SMRG) at the negative side.
Page 44 TH-44 THS II (TOYOTA HYBRID SYSTEM II) 3) Power is OFF D First, the THS ECU turns the SMRG OFF. After it has determined whether the contact points of the SMRG are stuck, it turns the SMRB OFF. D Afterwards, the THS ECU turns the SMRP ON in order to determine whether the contact points of the SMRB are stuck.
Page 45 TH-45 THS II (TOYOTA HYBRID SYSTEM II) Cooling Fan Control for HV Battery D The THS ECU monitors rises in the battery temperature through the four temperature sensors in the HV battery module. Then, the THS ECU steplessly actuates the cooling fan under duty cycle control, in order to maintain the temperature of the HV battery module within the specified range.
Page 46 TH-46 THS II (TOYOTA HYBRID SYSTEM II) Auxiliary Battery Charging Control 1) General The THS ECU controls the DC/DC converter in accordance with the signals from the battery temperature sensor of the auxiliary battery, in order to control the charging voltage to the auxiliary battery.
Page 47 TH-47 THS II (TOYOTA HYBRID SYSTEM II) 4. MG1 and MG2 Main Control General D MG1, which is rotated by the engine, generates high voltage (alternating current) in order to operate MG2 and charge the HV battery. Also, it functions as a starter to start the engine.
Page 48 TH-48 THS II (TOYOTA HYBRID SYSTEM II) Motor Generation Operation The illustration below describes the basic control for the motor to generate electricity. The current that is generated sequentially by the three phases of the motor, which is driven by the wheels, is utilized to charge the HV battery or drive another motor generator.
Page 49 TH-49 THS II (TOYOTA HYBRID SYSTEM II) 5. Inverter Assembly Control General D The inverter converts the direct current from the HV battery into an alternating current for MG1 and MG2, or vice versa, in accordance with the signals provided by the THS ECU via the MG ECU. In addition, the inverter supplies the alternating current from the MG1 power to the alternating current for MG2.
Page 50 TH-50 THS II (TOYOTA HYBRID SYSTEM II) Boost Converter Control 1) General D The boost converter boosts the nominal voltage of DC 244.8 V (for the HV battery) up to a maximum voltage of DC 650 V, in accordance with the signals provided by the THS ECU via the MG ECU.
Page 51 TH-51 THS II (TOYOTA HYBRID SYSTEM II) 3) Voltage Drop Conversion Function The alternating current, which is generated by MG1 or MG2 for the purpose of charging the HV battery, is converted into maximum voltage of DC 650 V by the inverter. Then, a function of the boost converter drops the voltage to nominal voltage of DC 244.8 V.
Page 52 TH-52 THS II (TOYOTA HYBRID SYSTEM II) 6. Skid Control ECU Control D The skid control ECU calculates the total braking force needed, based on the master cylinder pressure in the brake actuator and brake pedal stroke sensor generated when the driver depresses the brake pedal.
Page 53 TH-53 THS II (TOYOTA HYBRID SYSTEM II) 7. Battery Control D The battery smart unit detects and transmits the HV battery condition signals (voltages, currents, and temperatures), which are used to determine charging or discharging values, to the THS ECU.
Page 54 TH-54 THS II (TOYOTA HYBRID SYSTEM II) 8. During Collision Control General If the vehicle encounters one of the situations described below, the THS ECU will shut down the entire power supply by turning the SMR (System Main Relay) OFF, in order to ensure safety.
Page 55 TH-55 THS II (TOYOTA HYBRID SYSTEM II) 9. Indicator and Warning Light Illumination Control Energy Monitor D On the ’07 Camry Hybrid model, the multi-information display located on the combination meter has a function to display the energy flow, which enables the driver to monitor the driving conditions of the vehicle.
Page 56 TH-56 THS II (TOYOTA HYBRID SYSTEM II) Indicator and Warning Light 1) Combination Meter In particular, the indicator and warning lights associated with the THS II are described below. Master Warning Light Combination Meter Malfunction Discharge Indicator Lamp Warning Light...
Page 57 TH-57 THS II (TOYOTA HYBRID SYSTEM II) 2) Multi-Information Display D This warning display indicates to the driver that the SOC is lower than the minimum standard value (%). At the same time, the master warning light blinks and the buzzer sounds.
Page 58 TH-58 THS II (TOYOTA HYBRID SYSTEM II) 10. Diagnosis D In the THS II, if the THS ECU detects a malfunction, the ECU performs a diagnosis and memorizes failed sections. Furthermore, to inform the driver of the malfunction, the ECU illuminates or blinks the MIL (Malfunction Indicator Lamp), master warning light, which pertains to the ECU.
Page 59: Exterior Appearance
MO-2 NEW MODEL OUTLINE EXTERIOR APPEARANCE Front View 02HMO01TE Rear View 02HMO02TE...
Page 60: Model Code
MO-3 NEW MODEL OUTLINE MODEL CODE AHV40 L - A E X G B A BASIC MODEL CODE GEAR SHIFT TYPE AHV40: With 2AZ-FXE Engine X: Automatic, Floor STEERING WHEEL POSITION GRADE L: Left-Hand Drive G: — MODEL NAME ENGINE SPECIFICATION A: Camry B: Atkinson BODY TYPE...
Page 61: Front View
MO-4 NEW MODEL OUTLINE EXTERIOR Front View D Dynamic modernism has been produced by providing a solid-looking hood shape from the front grille to the center of the hood and framing the hood with the left and right fenders. D The front design, with minimum surface boundaries between the hood, grill, top mark and bumper, stretches out from the impressively projecting top mark and incorporates a coated front grill to make it distinctive from gasoline engine models.
Page 62: Side View
MO-5 NEW MODEL OUTLINE Side View In order to express a dynamic 3-dimensional form, the extruded front and rear fender shapes have been incorporated into the body design, which is based on straight lines. 02HMO07TE Tire & Disc Wheel Tire Size P215/60R16 Size...
Page 63: Instrument Panel
MO-6 NEW MODEL OUTLINE INTERIOR Instrument Panel A light, sporty and open feel has been achieved with lines that flow from the center cluster to both left and right, seemingly floating on the instrument panel lower. 02HMO10TE Center Cluster D The center cluster has been designed to be fresh and clear. By making the LCD (liquid Crystal Display) screen larger and putting the screen and the switches closer together, both ease of use and freshness have been achieved.
Page 64: Combination Meter
The brightness of the meter rings has 4 levels and increases in accordance with improvements in the average fuel economy since the THS II (Toyota Hybrid System II) started. D The multi-information display is provided in the center of the speedometer.
Page 65: Shift Lever
MO-8 NEW MODEL OUTLINE Shift Lever D A 5-position (P, R, N, D, and B) gate type floor shift lever is used. D A leather covered shift knob is used. Gate Type Floor Shift Lever 02HMO12Y Steering Wheel D A 4-spoke leather-wrapped steering wheel is provided. D A newly designed steering pad switch is used, which allows the audio system, automatic air conditioning system, multi-information display, telephone and navigation voice recognition systems to be easily operated.
Page 66: Rear Seat
MO-9 NEW MODEL OUTLINE Rear Seat A fold-down function has been provided for the rear seat. By allowing the seat lock to be released from the trunk compartment, convenience has been improved. Foldable 40/60 Split Type Seat Seat Lock Release Lever Seat Lock Seat Lock Release Lever 02HMO23Y...
Page 67 EQUIPMENT THS II (Toyota Hybrid System II) D The ’07 Camry Hybrid model is powered by a THS II (Toyota Hybrid System II), which has been developed under a “Hybrid Synergy Drive” concept to pursue better environmental performance and to realize “fun to drive”...
Page 68 MO-11 NEW MODEL OUTLINE Navigation with AV System Navigation System D Through the use of the GPS (Global Positioning System) and the map data in a DVD (Digital Versatile Disc), the navigation with AV (Audio Visual) system analyzes the position of the vehicle and indicates that position on the map that is displayed on the screen.
Page 69 MO-12 NEW MODEL OUTLINE Energy Monitor Screen D The following screens can be displayed on the LCD of the AV system: energy monitor screen and fuel consumption screen. D The energy monitor screen indicates the current energy transmission direction and the SOC (state of charge) of the battery.
Page 70: Audio System
MO-13 NEW MODEL OUTLINE Audio System D The large and varied original LCD panels and large switched have been provided for each audio head unit, improving visibility and ease of use. D JBL’s Premium Sound System, consisting of their stereo amplifier and speaker system, has been provided as standard.
Page 71 MO-14 NEW MODEL OUTLINE Speaker " Speaker Location 02HMO16Y " Speaker Specifications Input Location Speaker Type Caliber Impedance Rated 2 Ω Front Tweeter x 2 65 mm (2.6 in.) 20 W 150 x 225 mm 2.2 Ω Front Midrange x 2 36 W (6.0 x 9.0 in.) 150 x 225 mm...
Page 72 MO-15 NEW MODEL OUTLINE Bluetooth Hands-free System D Bluetooth is a high-speed wireless data communication system that uses the 2.4 GHz frequency band prescribed by the Bluetooth SIG (Special Interest Group), with a communication speed of 1 Mbps. By simply bringing a cellular phone that has been pre-registered on the audio head unit or the multi display into the vehicle, the user can talk hands-free.
Page 73 THS II* without the use of the key, as long as the user has the key in his/her possession. 025MO35Y 025MO44Y Door Unlock Door Lock 02HMO25Y 02HMO27Y THS II* Start Trunk Open *: Toyota Hybrid System II...
Page 74 MO-17 NEW MODEL OUTLINE Glass UV reduction glass, which blocks the ultraviolet rays in the sunlight, is used to ensure comfort. 02HMO18TE Ultraviolet Visible Light Glass Portion Color Glass Type Reduction Rate Penetration Rate Green with Dark y70% Windshield Laminated Shade Tempered &...
Page 75 MO-18 NEW MODEL OUTLINE PERFORMANCE Power Train System Performance Maximum System Output* 144 kW (192 HP) : The maximum output indicates engine output + HV battery output Engine Type 2AZ-FXE No. of Cylinders & 4-Cylinder, In-line Arrangement 16-Valve DOHC, Valve Mechanism Chain Drive (with VVT-i) 2362 cm Displacement...
Page 76 MO-19 NEW MODEL OUTLINE Motor and Generator Item (Motor Generator No.1) (Motor Generator No.2) Type Permanent Magnet Motor Permanent Magnet Motor Function Generate, Engine Starter Generate, Drive Wheels Max. Voltage DC650 V DC650 V 105 kW Max. Output — (143 HP) 270 N Max.
Page 77 MO-20 NEW MODEL OUTLINE Chassis Suspension Front Suspension Rear Suspension MacPherson Strut Type Dual Link MacPherson Strut Type Independent Suspension Independent Suspension 02HMO21Y Steering Steering Type Electric Power Steering Gear Type Rack & Pinion Brake Front Brake Type Ventilated Disc Front Rotor Size 296 mm (11.65 in.) Rear Brake Type...
Page 78 ENVIRONMENT and RECYCLING Adoption of TSOP & TPO TSOP (Toyota Super Olefin Polymer), TPO (Thermoplastic Olefin), which have superior recyclability, are actively utilized while the use of chlorine has been reduced as much as possible. : TSOP (Toyota Super Olefin Polymer)
Page 79 MO-22 NEW MODEL OUTLINE DIMENSIONS 150 mm (5.9 in.) 945 mm (37.2 in.) 2775 mm (109.3 in.) 1085 mm (42.7 in.) 4805 mm (189.2 in.) 02HMO08TE 1460 mm (57.5 in.) Front 1575 mm (62.0 in.) Rear 1565 mm (61.6 in.) 1820 mm (71.7 in.) 02HMO09TE...
Page 80 MO-23 NEW MODEL OUTLINE EQUIPMENT LIST F: Standard OP: Option Radiator Grille Chrome Plated Exterior Front Fairing Fairing Rear Tire P215 / 60R16 94V Disc Wheel 16 x 6 1 / 2 J Aluminum VDIM (Vehicle Dynamics Integrated Management) Brake Control Brake Control ECB (Electronically Controlled Brake System) Chassis...
Page 81 MO-24 NEW MODEL OUTLINE F: Standard OP: Option Electric Remote Control Outside Rear View Mirror Outside Rear View Mirror Electric Remote Control with Heater Compass Display Inside Rear View Mirror Automatic Glare-resistance EC Mirror Sliding Roof AM / FM Tuner, In-dash 6-CD Changer, Audio Body Bluetooth , JBL Amplifier and 8 Speakers...
Page 82: Body Structure
BO-2 BODY - BODY STRUCTURE BODY BODY STRUCTURE JLIGHTWEIGHT AND HIGHLY RIGID BODY 1. High Strength Sheet Steel D High strength sheet steel is used in order to ensure body rigidity and realize a lightweight body. D In the center pillar reinforcement, roof reinforcement, rocker outer and rocker inner, ultra high strength sheet steel is used.
Page 83 BO-3 BODY - BODY STRUCTURE 2. Brace Excellent maneuverability and stability has been achieved by providing a cowl top outer panel for the front suspension tower. Tightened on the top of Suspension Tower Cowl Top Outer Panel 025BO02Y...
Page 84 BO-4 BODY - BODY STRUCTURE JSAFETY FEATURES 1. General The impact absorbing structure of the ’07 Camry Hybrid models minimizes cabin deformation by effectively helping to absorb the impact energy in the event of a front, side or rear collision. This provides high-performance occupant protection.
Page 85 BO-5 BODY - BODY STRUCTURE 3. Impact Absorbing Structure for Side Collision The impact energy of a side collision directed to the cabin area is dispersed throughout the body via the pillar reinforcements, side impact protection beams, and floor cross members, thus helping minimize the impact energy finally directed to the cabin.
Page 86 BO-6 BODY - BODY STRUCTURE D Seat pipes and seat pads have been provided on the front seat pillar frame for load conduction. Furthermore, the tunnel box has been reinforced. Thus, input load is conducted from the pillar and door to the seat, tunnel box and opposite seat, minimizing deformation of the body.
Page 87 BO-7 BODY - BODY STRUCTURE 4. Impact Absorbing Structure for Rear Collision Rear floor side members and reinforcements have been optimally allocated to control body deformation mode during a collision. Rear Floor Side Member Reinforcement V-notched Upper Outside Front 02HBO16Y...
Page 88 BO-8 BODY - BODY STRUCTURE 5. Lessening Pedestrian Head Injury D A longitudinal frame is used as the principle structure of the hood inner, giving uniform rigidity to the hood surface. Hood Hood Inner 025BO09Y D The rear wall of the cowl has been opened, so that it can easily collapse in the direction of an impact. Thus, a completely collapsible structure has been realized.
Page 89 BO-9 BODY - BODY STRUCTURE D Energy absorbing brackets are used in the joint portion of the front fender. Thus, a certain deformation stroke in the event of a head form collision has been ensured, reducing the impact. Head Form Front Fender Front Fender...
Page 90 BO-10 BODY - BODY STRUCTURE JRUST-RESISTANT BODY 1. General Rust-resistant performance is enhanced extensive use of anti-corrosion sheet steel, as well as by an anti-corrosion treatment that includes the application of anti-rust wax, sealer and anti-chipping paint to easily corroded parts such as the hood, doors. 2.
Page 91 BO-11 BODY - BODY STRUCTURE 4. Under Coat Acrylic acid resin is applied to under side of the body, inside the rear wheel housing and other parts that are susceptible to stone chipping damage, thus improving the rust-resistant performance of these areas. : Edge Seal : Acrylic Acid Resin Coating View from Bottom Side...
Page 92 BO-12 BODY - BODY STRUCTURE JLOW VIBRATION AND LOW NOISE BODY 1. General Effective application of vibration damping and noise suppressant materials reduces engine and road noises. The high-density silencer is used around the engine room and the instrument panel, thus, realizing improvement of the acoustic absorption and sound insulation and reduction in the engine transmission noise, compared with the gasoline engine model.
Page 93 BO-13 BODY - BODY STRUCTURE D In place of the asphalt sheet used on conventional models, a vibration damping foam coating is used on the floor of the new model to reduce road noise. D The thickness of the vibration damping foam coating has been optimally adjusted for the individual portions.
Page 94 BO-14 BODY - BODY STRUCTURE 3. Reducing Wind Noise D A structure that blocks the airflow is used in a portion of the door weather strip (at the front corner) in order to reduce wind noise (A - A cross section). D The air turbulence has been eliminated through the use of the hood side seal rubber (B - B cross section).
Page 95 BO-15 BODY - BODY STRUCTURE D Fender seals made of foamed resin are used between the front fender and the side member outer to prevent air from blowing through. (E - E cross section) D Parting seals made of flexible resin are employed between the front and rear doors to eliminate air turbulence (F - F cross sections).
Page 96 BO-16 BODY - BODY STRUCTURE JAERODYNAMICS To improve aerodynamic performance, the following measures have been taken. D Front and rear fairings are provided to smooth out the airflow around the tires and reduce the air resistance while the vehicle is in motion. Rear Fairing Front Fairing 02HBO14TE...
Page 97 BO-17 BODY - BODY STRUCTURE D The use of the rectification parts and the flat vehicle bottom provides smooth airflow underneath the vehicle. Engine Under Cover LH Rear Floor Cover Fuel Tank Cover No.2 Front Faring Rear Faring Rear Faring Front Faring Fuel Tank Cover No.1 Engine Under Cover RH...
Page 98 BO-18 BODY - ENHANCEMENT OF PRODUCT APPEAL ENHANCEMENT OF PRODUCT APPEAL JPARTS WITH LOW REPAIR COST D The plating portion of the front grille has been redesigned as an individual part. As a result, replacing only damaged parts is possible, reducing repair costs. Radiator Grille Plating Portion 02HBO04Y...
Page 99 BO-19 BODY - ENHANCEMENT OF PRODUCT APPEAL JWASHER NOZZLE Spray type washer nozzles are located under the engine hood to ensure good appearance. These nozzles can spray windshield washer fluid over a wide area by spraying it in a fan shape. The washer fluid volume has been reduced so as not to hinder the driver’s view when washer system is operated.
Page 100 BO-20 BODY - ENHANCEMENT OF PRODUCT APPEAL JINTERNAL TRUNK RELEASE HANDLE In case a person is inadvertently locked inside the trunk and needs to get out, an internal trunk release handle is included inside the luggage room. The handle is made of phosphorescent plastic, so that it is visible in the luggage room for a while even after the luggage room door has been closed.
Page 101 BO-21 BODY - ENHANCEMENT OF PRODUCT APPEAL JSEAT BELT 1. General The following types of seat belts are provided. Seat Position Seat Belt Type Remarks Electrical Sensing type Driver 3-point ELR* Pretensioner and Force Limiter Electrical Sensing type Front Passenger 3-point ELR* &...
Page 102 BO-22 - MEMO -...
Page 103 CH-2 CHASSIS - P311 HYBRID TRANSAXLE JATF (AUTOMATIC TRANSMISSION FLUID) WS D ATF WS is used to reduce the resistance of the ATF and improve the fuel economy by reducing its viscosity in the practical operating temperature range. At higher fluid temperatures, the viscosity is the same as that of ATF Type T-IV, which ensures the durability of the automatic transaxle.
Page 104 CH-2 CHASSIS - P311 HYBRID TRANSAXLE CHASSIS P311 HYBRID TRANSAXLE JDESCRIPTION D The P311 hybrid transaxle is used on the ’07 Camry Hybrid model. D Containing a MG2 (Motor Generator No.2) for driving the vehicle and a MG1 (Motor Generator No.1) for generating electrical power, this hybrid transaxle uses a continuously variable transmission mechanism with compound gear unit (which consists of a motor speed reduction planetary gear unit and a power split planetary gear unit) that achieve smooth and quiet operation.
Page 105 Total Deceleration Ratio 3.542 Oil Capacity Liters (US qts, Imp. qts) 3.8 (4.0, 3.3) Oil Type Toyota Genuine ATF WS Weight (Reference)* kg (lb) 113.3 (249.8) *: Weight shows the figure with the fluid fully filled. Compound Gear Unit Transaxle Damper...
Page 106 CH-5 CHASSIS - P311 HYBRID TRANSAXLE JLUBRICATION MECHANISM D This transaxle is lubricated by a trochoid type oil pump placed on the main shaft. D Furthermore, it uses a final gear with an oil sling type lubrication mechanism. This construction minimizes the drive torque of the oil pump, which reduces the drive loss.
Page 107 CH-5 CHASSIS - P311 HYBRID TRANSAXLE JTRANSAXLE UNIT 1. General D This hybrid transaxle consists primarily of MG1 and MG2, a compound gear unit (which consists of a motor speed reduction planetary gear unit and a power split planetary gear unit), a counter gear unit, and a differential gear unit.
Page 108 CH-6 CHASSIS - P311 HYBRID TRANSAXLE 2. Compound Gear Unit General The compound gear unit consists of a motor speed reduction planetary gear, and a power split planetary gear. Each planetary ring gear is integrated with the compound gear. Furthermore, this compound gear is integrated with a counter drive gear and parking gear.
Page 109 CH-7 CHASSIS - P311 HYBRID TRANSAXLE Power Split Planetary Gear The power split planetary gear in the compound gear unit transmits the motive force in the four ways described below. D The engine motive force, which is input by the carrier, is output to the ring gear. Furthermore, the MG2 motive force is output to the ring gear via the motor speed reduction planetary gear.
Page 110 CH-8 CHASSIS - P311 HYBRID TRANSAXLE D The engine motive force, which is input by the carrier, is output to the sun gear. Thus, the motive force is transmitted in order to operate MG1 as a generator. Motor Speed Reduction Power Split Planetary Gear Planetary Gear...
Page 111 CH-9 CHASSIS - P311 HYBRID TRANSAXLE Motor Speed Reduction Planetary Gear The carrier of the motor speed reduction planetary gear, which is located in the compound gear unit, is fixed. The MG2 motive force is input by the sun gear and is output to the ring gear, in order to drive the wheels. For this reason, the motor speed reduction planetary gear has a function to reduce the speed of MG2 and increase torque, in accordance with a set gear ratio.
Page 112 CH-10 CHASSIS - P311 HYBRID TRANSAXLE 4. Differential Gear Unit For the differential gear unit, a 2-pinion type that is similar to the differential unit of the conventional transaxle is used. 5. Transaxle Damper A transaxle damper that consists of 4 coil springs with low-twist characteristics is used in order to absorb the torque fluctuation in the drive force of the engine.
Page 113 CH-12 CHASSIS - P311 HYBRID TRANSAXLE JSHIFT CONTROL SYSTEM 1. Shift Control D A shift position sensor is provided in the transaxle to detect the shift position and sends a corresponding signal to the THS ECU. Upon receiving this signal, the THS ECU optimally combines the operation of the engine, MG1 and MG2 in order to produce the respective shift positions (“P”, “R”, “N”, “D”, and “B”).
Page 114 CH-13 CHASSIS - P311 HYBRID TRANSAXLE 2. Parking Lock Mechanism D A mechanical parking lock mechanism has been provided in the compound gear. The engagement of the parking lock pawl with the parking gear that is integrated with the compound gear locks the movement of the vehicle.
Page 115 CH-14 CHASSIS - P311 HYBRID TRANSAXLE 3. Shift Lever D A 5-position (P, R, N, D, and B) gate type shift lever is used. The gate type shift lever operates on the single-shift operation principle (fore-aft and side-to-side). Therefore, it does not require the use of a shift lever button, which is used on a straight type shift lever.
Page 116 CH-15 CHASSIS - P311 HYBRID TRANSAXLE 4. Shift Lock System General D The shift lock mechanism prevents the shift lever from being shifted to any position other than the P position, unless the IG-ON mode is selected, and the brake pedal is depressed. This mechanism helps to prevent unintentional acceleration.
Page 117: Drive Shaft
CH-16 CHASSIS - DRIVE SHAFT DRIVE SHAFT JDESCRIPTION The drive shaft uses a tripod type CVJ (Constant Velocity Joint) on the differential side, and Rzeppa type CVJ on the wheel side. Rzeppa Type CVJ Tripod Type CVJ Wheel Differential Side Side Left-Hand 02HCH43Y...
Page 118 CH-17 CHASSIS - SUSPENSION AND AXLE SUSPENSION AND AXLE JSUSPENSION 1. General D MacPherson strut type independent suspension is used for the front. D Dual link MacPherson strut type independent suspension is used for the rear. 02HCH45Y " Specifications Type MacPherson Strut Tread mm (in.)
Page 119 CH-18 CHASSIS - SUSPENSION AND AXLE 2. Front Suspension General D Through the optimal location of components, and the use of Nachlauf geometry, the front suspension provides excellent riding comfort and controllability. D Low-pressure (N ) gas sealed type construction is used to suppress cavitation. Upper Support Coil Spring D Optimized characteristics...
Page 120 CH-19 CHASSIS - SUSPENSION AND AXLE 3. Rear Suspension General Rear suspension realizes excellent stability and controllability by optimizing the suspension geometry and the allocation of components. Upper Support Coil Spring D Optimized characteristics D Optimized spring rate Shock Absorber D Low-pressure (N ) gas is sealed Lower Arm No.2 Bushing...
Page 121 CH-20 CHASSIS - SUSPENSION AND AXLE Cornering Geometry When a lateral force is generated, the load becomes distributed to the No.1 and No.2 suspension arms. The illustration shown below indicates the lateral force distribution on suspension arms of the right side rear wheel during left cornering.
Page 122 CH-21 CHASSIS - SUSPENSION AND AXLE JAXLE 1. Front Axle D The front axle uses compact and highly double-row angular ball bearings. The bearings and the axle hub have been integrated to ensure high rigidity, thus realizing excellent driving and braking stability. D A lock nut (12-point) is used and staked in order to ensure that the axle hub is properly secured.
Page 123 Rotor Size (D x T)* mm (in.) (11.06 x 0.39) Pad Material D6234 Type Duo Servo Parking Brake Parking Brake Drum Inner Dia. mm (in.) 170.0 (6.69) TOYOTA Brake Actuator Manufacturer (In-house Sourcing Parts) *: D: Outer Diameter, T: Thickness...
Page 124 CH-23 CHASSIS - BRAKE 2. Component of Brake System Brake Actuator Parking Brake Pedal Pump Motor Adjusting Accumulator Master Cylinder and Stroke Simulator Master Cylinder Stroke Simulator Master Cylinder Cross Section 02HCH01Y...
Page 125 CH-24 CHASSIS - BRAKE JFRONT BRAKE D The diameter of the front rotor is 296 mm (11.65 in.). The front rotor is the ventilated type that excels in heat dissipation to ensure reliability. D The shape of the front dust cover has been optimized to efficiently direct cool air to the ventilated disc, thus ensuring excellent cooling performance.
Page 126 CH-25 CHASSIS - BRAKE JBRAKE CONTROL SYSTEM 1. General D A brake management function, VDIM (Vehicle Dynamics Integrated Management), which delivers comprehensive vehicle movement control, is used. D An ECB (Electronically Controlled Brake System) is used. D The brake control system is controlled by the skid control ECU. 2.
Page 127 CH-26 CHASSIS - BRAKE Examples of Control Operation 1) General The difference in vehicle control during harsh braking situations while cornering, with the VDIM and conventional brake control systems, is as follows: 2) Conventional Conventional brake control systems calculate vehicle motion based on signals transmitted by yaw rate and deceleration sensors, the speed sensors and the steering sensor, and activates VSC systems when vehicles are determined to be skidding.
Page 128 CH-27 CHASSIS - BRAKE Control Configuration of VDIM Skid Control ECU Sensors Hybrid System Target Vehicle Behavior Calculation Vehicle Condition Calculation Control Value Calculation Brake System Steering System 277CH145 Function The brake control system of the ’07 Camry Hybrid model has a following function: Brake Control Function...
Page 129 CH-28 CHASSIS - BRAKE Outline of Regenerative Brake Cooperative Control Function 1) General D Regenerative brake consists of a resistance force that is generated at the rotational axle in the reverse direction of the rotation of the generator (MG2) that is generating electricity. The greater the generated amperage (battery charging amperage), the greater will be the resistance force.
Page 130 CH-29 CHASSIS - BRAKE 2) Apportioning of the Brake Force D The apportioning of the brake force between the hydraulic brake and the regenerative brake varies by the vehicle speed and time. D The apportioning of the brake force between the hydraulic brake and the regenerative brake is accomplished by controlling the hydraulic brake so that the total brake force of the hydraulic brake and the regenerative brake matches the brake force required by the driver.
Page 131 CH-30 CHASSIS - BRAKE Outline of Power Steering Cooperative Control Function 1) General D The VDIM effects coordinated control consisting of the ECB (Electronically Controlled Brake System) and EPS. By integrating these preventive safety functions, the VDIM ensures excellent driving stability and maneuverability of the vehicle. D The VDIM coordinates the EPS and ECB (Electronically Controlled Brake System) to perform braking control on split friction roads and front and rear wheel skid tendency controls.
Page 132 CH-31 CHASSIS - BRAKE 2) Operation in Braking on Split Friction Roads When braking on a split friction road, the vehicle tends to deflect toward the higher friction side due to the difference between the braking forces on the left and right sides. In the VDIM, the EPS ECU receives command signals from the skid control ECU.
Page 133 CH-32 CHASSIS - BRAKE 4) Operation in Front Wheel Skid Tendency Control D When front wheel skidding is detected, motive force is limited and braking control is performed based on the amount of front wheel skid tendency. Accordingly, a moment of force is generated in the vehicle turning direction to limit front wheel skid tendency.
Page 134 CH-33 CHASSIS - BRAKE 3. ECB (Electronically Controlled Brake System) General D In this system, the conventional brake booster portion has been discontinued. Instead, it consists of brake input, power supply, and hydraulic pressure control portions. D During normal braking, the fluid pressure generated by the master cylinder does not directly actuate the wheel cylinders, but serves as a hydraulic pressure signal.
Page 135 CH-34 CHASSIS - BRAKE Outline of EBD Control Function 1) General The distribution of the brake force, which was performed mechanically in the past, is now performed under electrical control of the skid control ECU, which precisely controls the braking force in accordance with the vehicle’s driving conditions.
Page 136 CH-35 CHASSIS - BRAKE Outline of Brake Assist Function The brake assist function interprets a quick push of the brake pedal as emergency braking and supplements the braking power applied if the driver has not stepped hard enough on the brake pedal. In emergencies, drivers, especially inexperienced ones, often panic and do not apply sufficient pressure on the brake pedal.
Page 137 CH-36 CHASSIS - BRAKE Outline of TRAC Function D If the driver presses the accelerator pedal aggressively when starting off or accelerating on a slippery surface, the drive wheel could slip due to the excessive amount of torque that is generated. The adjustment of the motive force and the control of the hydraulic brakes of the drive wheels accomplished by THS II allow the TRAC function to help minimize the slippage of the drive wheels, and generate the drive force that is appropriate for the road surface conditions.
Page 138 CH-37 CHASSIS - BRAKE Outline of VSC Function 1) General The followings are two examples that can be considered as circumstances in which the tires exceed their lateral grip limit. The VSC function is designed to help control the vehicle behavior by controlling the motive force and the brakes at each wheel when the vehicle is under one of the conditions indicated below.
Page 139 CH-38 CHASSIS - BRAKE b. Determining Rear Wheel Skid Direction of Travel of the Vehicle’s Whether or not the vehicle is in the state of Center of Gravity rear wheel skid is determined by the values Movement of Vehicle of the vehicle’s slip angle and the vehicle’s Slip Angle slip angular...
Page 140 CH-39 CHASSIS - BRAKE System Diagram Brake Pedal Stroke Sensor Brake Fluid Level Stop Light Switch Warning Switch Brake Stroke Simulator Brake Speed Actuator Sensors Speed Sensors ECB* MTR1 Relay Parking Brake Switch ECB* MTR2 Relay Battery (12 V) ECB* MAIN1 Relay VSC Warning Buzzer Skid Control ECU ECB* MAIN2 Relay...
Page 141 CH-40 CHASSIS - BRAKE Construction The configuration of the brake control system is as shown in the following chart. BRAKE ACTUATOR SPEED SENSOR (FL) SMC1 Master Cylinder Cut Solenoid Valve 1 SPEED SENSOR (FR) Master Cylinder Cut SMC2 Solenoid Valve 2 SPEED SENSOR (RL) Pressure Appliance Solenoid Valve (FL)
Page 142 CH-41 CHASSIS - BRAKE VSC WARNING BUZZER Wheel Cylinder Pressure Sensor (FL) DATA LINK CONNECTOR 3 CAN (CAN No.1 Bus) CANL Wheel Cylinder STEERING ANGLE SENSOR Pressure Sensor (FR) CANH YAW RATE AND DECELERATION RATE SENSOR Wheel Cylinder Pressure Sensor (RL) THS ECU SKID Wheel Cylinder...
Page 143 CH-42 CHASSIS - BRAKE Layout of Main Components Multi-information Display Slip Indicator Light ABS Warning Light ECB* Warning Light Brake System Master Warning Light Warning Light Steering Angle Sensor VSC Warning Buzzer Skid Control ECU Parking Brake Switch Brake Pedal Stroke Sensor DLC3 Yaw Rate and...
Page 144 CH-43 CHASSIS - BRAKE Function of Main Components Component Function D Consists of a pump, pump motor, accumulator, and relief valve, Hydraulic and generates and stores the hydraulic pressure, which the skid Power Source control ECU uses for controlling braking. D The accumulator pressure sensor is installed in the brake Portion actuator.
Page 145 CH-44 CHASSIS - BRAKE Component Function D Sounds continuously to inform the driver that there is a malfunction in the hydraulic pressure or a failure in the power VSC Warning Buzzer supply. D Sounds intermittently to inform the driver of the vehicle skidding.
Page 146 CH-45 CHASSIS - BRAKE Construction and Operation of Main Components 1) Brake Actuator a. General D The brake actuator consists of hydraulic control and hydraulic power source portions. D The two master cylinder pressure sensors, four wheel cylinder pressure sensors, and an accumulator pressure sensor are installed in the brake actuator.
Page 147 CH-46 CHASSIS - BRAKE b. Hydraulic Control Portion The 10 solenoid valves and 6-pressure sensors consists of the following: D 2 master cylinder cut solenoid valves [(1), (2)] D 4 pressure appliance valves [(3), (4), (5), (6)] D 4 pressure reduction valves [(7), (8), (9), (10)] D 2 master cylinder pressure sensors [(a), (b)] D 4 wheel cylinder pressure sensors [(c), (d), (e), (f)] "...
Page 148 CH-47 CHASSIS - BRAKE c. Hydraulic Power Source Portion i) General The hydraulic power source portion consists of pump, pump motor, accumulator, relief valve, 2 motor relays, and accumulator pressure sensor. ii) Accumulator Inside the accumulator, the high-pressurized nitrogen gas is charged and sealed. In addition, metallic bellows-formed tube is used, in order to enhance the gastight performance of the accumulator.
Page 149 CH-48 CHASSIS - BRAKE iv) Operation D The brake fluid that is discharged by the pump passes through the check valve and is stored in the accumulator. The hydraulic pressure that is stored in the accumulator is used for providing the hydraulic pressure that is needed for normal braking and for operating the brake control.
Page 150 CH-49 CHASSIS - BRAKE D If the accumulator pressure drops abnormally to a level below the pressure set at the ECU, the skid control ECU illuminates the brake system warning light, the ECB* warning light, ABS warning light and the master warning light. Then, a warning message appears on the multi-information display in the combination meter, and the VSC warning buzzer sounds to alert the driver of the abnormal hydraulic pressure.
Page 151 CH-50 CHASSIS - BRAKE 2) Brake Pedal Stroke Sensor This sensor, which contains a contact type variable resistor, detects the extent of the brake pedal stroke and transmits it to the skid control ECU. Return Spring Sensor Shaft Brake Pedal Lever Contacts Stroke Sensor...
Page 152 CH-51 CHASSIS - BRAKE 3) Stroke Simulator D The stroke simulator is mounted between the master cylinder and the brake actuator. The fluid pressure generated by the master cylinder is introduced to the stroke simulator through the built-in stroke simulator cut valve. D The stroke simulator generates a pedal stroke in accordance with the driver’s pedal effort during braking.
Page 153 CH-52 CHASSIS - BRAKE 5) Steering Angle Sensor D The steering angle sensor detects the steering direction and angle, and sends this signal to the skid control ECU. D The sensor contains two gears for detecting the rotational movement. The magnetic field of the MRE (Magnetic Resistance Element), which is built into these gears, changes as the gears rotate.
Page 154 CH-53 CHASSIS - BRAKE System Operation 1) Normal Brake Operation (with Regenerative Brake Cooperative Control) a. General D During normal braking, the master cylinder cut solenoid valves are closed and the fluid pressure circuits to the wheel cylinders remain independent. Accordingly, the fluid pressure generated by the master cylinder will not directly cause the wheel cylinders to actuate.
Page 155 CH-54 CHASSIS - BRAKE b. Pressure Increase The skid control ECU calculates the target wheel cylinder pressure (equivalent to the brake force required by the driver) in accordance with the signals received from the master cylinder pressure sensor and the brake pedal stroke sensor. The skid control ECU compares the wheel cylinder pressure sensor signal and the target wheel cylinder pressure.
Page 156 CH-55 CHASSIS - BRAKE c. Holding The skid control ECU calculates the target wheel cylinder pressure (equivalent to the brake force required by the driver) in accordance with the signals received from the master cylinder pressure sensor and the brake pedal stroke sensor. The skid control ECU compares the wheel cylinder pressure signal with the target wheel cylinder pressure.
Page 157 CH-56 CHASSIS - BRAKE d. Pressure Reduce The skid control ECU calculates the target wheel cylinder pressure (equivalent to the brake force required by the driver) in accordance with the signals received from the master cylinder pressure sensor and the brake pedal stroke sensor. The skid control ECU compares the wheel cylinder pressure signal with the target wheel cylinder pressure.
Page 158 CH-57 CHASSIS - BRAKE e. Brake System Stops or During Power Supply Malfunction If the brake system stops or no accumulator pressure is supplied due to some malfunction, the skid control ECU operates the fail-safe function. This function opens the master cylinder solenoid valve in the brake actuator, in order to secure a fluid passage between the master cylinder and the wheel cylinder.
Page 159 CH-58 CHASSIS - BRAKE 2) ABS with EBD Operation Based on the signals received from the four speed sensors, the skid control ECU calculates each wheel speed and deceleration, and checks wheel slipping conditions. And according to the slipping condition, the skid control ECU controls the pressure increase valve and pressure reduction valve in order to adjust the fluid pressure of the each wheel cylinder in the following 3 modes: pressure reduction, pressure holding, pressure increase modes.
Page 160 CH-59 CHASSIS - BRAKE Not Activated Normal Braking — — Activated Increase Mode Holding Mode Reduction Mode Port A Pressure Appliance Valve Port B Hydraulic Pressure Circuit Reduction Valve Reservoir From Wheel To Wheel Cylinder Cylinder 255CH151 255CH152 255CH153 Pressure Appliance ON (Half-Open*) OFF (Close)
Page 161 CH-60 CHASSIS - BRAKE 3) Brake Assist Operation In the event of emergency braking, the skid control ECU detects the driver’s intention based on the speed of the pressure increase in the master cylinder determined by the pressure sensor signal. If the ECU judges the need for the additional brake assist, additional fluid pressure is generated by the pump in the actuator and directed to the wheel cylinders.
Page 162 CH-61 CHASSIS - BRAKE Brake Pedal Stroke Simulator (11) Accumulator Master Port (K) Cylinder Pump Pressure Port (A) Sensor Port (B) Accumulator Port (E) Pressure Sensor Port (F) Port (C) Port (D) Port (G) Port (H) Port (J) Port (I) (10) Wheel Wheel...
Page 163 CH-62 CHASSIS - BRAKE 4) TRAC Operation D The fluid pressure generated by the pump is regulated by the pressure appliance solenoid valve and pressure reduction solenoid valve to the required pressure. Thus, the wheel cylinders of the drive wheels are controlled in the following 3 modes: pressure reduction, pressure holding, and pressure increase modes, to restrain the slippage of the drive wheels.
Page 164 CH-63 CHASSIS - BRAKE Brake Pedal Stroke Simulator Accumulator (11) Master Port (K) Cylinder Port (A) Pump Pressure Sensor Port (B) Accumulator Pressure Sensor Port (E) Port (F) Port (C) Port (D) Port (J) Port (H) Port (I) Port (G) (10) Wheel Wheel...
Page 165 CH-64 CHASSIS - BRAKE 5) VSC Operation a. General The VSC function controls the solenoid valves in order to send the fluid pressure stored in the accumulator to the brake wheel cylinders at the respective wheels, through routes that are different from those used during normal braking.
Page 166 CH-65 CHASSIS - BRAKE b. Front Wheel Skid Restraint Control (Turning to the Right) D In the front wheel skid tendency, this management function applies the brake to the rear wheels and front wheel of the outer side of the turn. Also, depending on whether the brake is ON or OFF and the condition of the vehicle, there are circumstances in which the brake might not be applied to the wheels even if those wheels are targeted for braking.
Page 167 CH-66 CHASSIS - BRAKE VSC Activated VSC not VSC not Item Increase Holding Reduction Activated Mode Mode Mode Master Cylinder Cut Solenoid Valve (1), (2) (1), (2) (Close) (Close) (Close) (Close) (Close) (Close) (Close) (Close) Port: (A), (B) Pressure Appliance Solenoid Valve (Close) (Close)
Page 168 CH-67 CHASSIS - BRAKE c. Rear Wheel Skid Restraint Control (Turning to the Right) D In rear wheel skid tendency, this management function applies the brake to the front wheel of the outer circle of the turn. In some cases, the skid control ECU applies the brake to the rear wheels, as necessary.
Page 169 CH-68 CHASSIS - BRAKE VSC Activated VSC not VSC not Item Increase Holding Reduction Activated Mode Mode Mode Master Cylinder Cut Solenoid Valve (1), (2) (1), (2) (Close) (Close) (Close) (Close) (Close) (Close) (Close) (Close) Port: (A), (B) Pressure Appliance Solenoid Valve (Close) (Close)
Page 170 CH-69 CHASSIS - BRAKE Skid Control ECU 1) Motive Force Control During a brake control operation (TRAC or VSC function), the skid control ECU outputs a motive force control request signal to the THS ECU. Upon receiving this signal, the THS ECU effects motive force control.
Page 171 CH-70 CHASSIS - BRAKE 2) Diagnosis D If a failure occurs in one of the sensors or actuators in the brake system, the skid control ECU informs the driver of the failure in the brake system by illuminating the ECB* warning light, brake system warning light, or ABS warning light in the combination meter, or displaying a VSC warning message/“CHECK VSC SYSTEM”...
Page 172: Tire Pressure Warning System
CH-71 CHASSIS - TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING SYSTEM JDESCRIPTION D A direct-sensing type tire pressure warning system is used on U.S.A. model. D If the vehicle continues to be driven with 1 or more of the 4 inflated to a low air pressure that could cause problems during driving, this system will illuminate the tire pressure warning light to inform the driver of the low air pressure.
Page 173 CH-72 CHASSIS - TIRE PRESSURE WARNING SYSTEM JLAYOUT OF MAIN COMPONENTS Tire Pressure Warning System Reset Switch Tire Pressure Warning System ECU Tire Pressure Warning System Antenna & Receiver Combination Meter D Tire Pressure Warning Light Tire Pressure Warning System Valve &...
Page 174 CH-73 CHASSIS - TIRE PRESSURE WARNING SYSTEM JCONSTRUCTION AND OPERATION 1. Tire Pressure Warning System Valve & Transmitter D The tire pressure warning system valve & transmitter is integrated in the air valve of a disc wheel. It measures the pressure and the temperature of the air in the tire and transmits the measured values and a recognition ID to the tire pressure warning system valve &...
Page 175 CH-74 CHASSIS - TIRE PRESSURE WARNING SYSTEM 2. Tire Pressure Warning System Antenna & Receiver and Tire Pressure Warning System ECU D The tire pressure warning system antenna & receiver, receives the radio wave signals from the tire pressure warning system valve & transmitter and transmits those signals to the tire pressure warning ECU. D The tire pressure warning system antenna &...
Page 176 CH-75 CHASSIS - TIRE PRESSURE WARNING SYSTEM 3. Tire Pressure Warning System Reset Switch D By operating the tire pressure warning system reset switch, tire pressure warning system ECU can be set to issue a warning at an inflation pressure that corresponds with the type of tires. Therefore, the dealer must set the warning threshold to the proper value in order to comply with the local regulations.
Page 177 CH-76 CHASSIS - TIRE PRESSURE WARNING SYSTEM 5. Self-Diagnosis If malfunctions are detected in the system, the tire pressure warning system ECU warns the driver by illuminating the tire pressure warning light after blinking it at 1 Hz intervals for 1 minute, and stores the DTC (Diagnostic Trouble Code) in the memory.
Page 178 CH-77 CHASSIS - TIRE PRESSURE WARNING SYSTEM DTC No. Detection Item DTC Deletion Condition Data from tire pressure warning system valve & C2181/81 transmitter registered to ID1 not received (test diagnosis) Data from tire pressure warning system valve & C2182/82 transmitter registered to ID2 not received (test diagnosis) When deletion conditions of the When deletion conditions of the...
Page 179 CH-78 CHASSIS - STEERING STEERING JDESCRIPTION D The ’07 Camry Hybrid model uses a vehicle-speed sensing type EPS (Electric Power Steering) as standard equipment. D A manual tilt and telescopic mechanism is used. D The steering column uses an energy absorbing mechanism. D An electrical steering lock system is used.
Page 180 CH-79 CHASSIS - STEERING JEPS (Electric Power Steering) 1. General D This system uses a motor and a reduction mechanism that are built into the steering gear housing to generate assist torque, in order to assist the driver’s steering effort. The EPS ECU calculates the amount of power assist in accordance with the signals provided by the sensors and the ECUs.
Page 181 CH-80 CHASSIS - STEERING 2. Layout of Main Components THS ECU EPS ECU Steering Gear Assembly D Torque Sensor D DC Motor P/S Warning Light D Rotation Angle Sensor Skid Control ECU DLC3 02HCH51TE...
Page 182 CH-81 CHASSIS - STEERING 3. Function of Main Components Components Function Detects the twist of the torsion bar with this, it calculates the torque Torque Sensor that is applied to the torsion bar by changing it into an electrical signal, and outputs this signal to the EPS ECU. Generates power assist in accordance with a signal received from Motor the EPS ECU.
Page 183 CH-82 CHASSIS - STEERING 4. Constructions and Operation Steering Gear Unit 1) General A motor, reduction mechanism, and the torque sensor are enclosed in the steering gear unit. Torque Sensor Portion Front Motor Portion Reduction Mechanism Portion 02HCH52Y 2) Motor D The motor is a high power output, brush less type motor is used.
Page 184 CH-83 CHASSIS - STEERING 3) Reduction Mechanism D The reduction mechanism consists of a high-precision rolled ball thread with a smooth surface, which realizes high efficiency and low noise. D The ball screw reduction gear has four ball directors, and is fixed to the rotor. D By the ball director, the ball is circulated endlessly the inside of the ball screw reduction gear.
Page 185 CH-84 CHASSIS - STEERING b. Torque Sensor Operation i) Straight-line Driving If the vehicle is driven straight and the driver dose not turn the steering wheel, the specified voltage that is output at this time is determined by the ECU to indicate the neutral position of the steering. Therefore, it dose not apply current to the motor.
Page 186 CH-85 CHASSIS - STEERING 5. EPS ECU 1) General D The EPS ECU receives signals from Assist various sensors, judges the current vehicle Power condition, and determines the assist current Current to be applied to the motor accordingly. Vehicle Output D The diagram on the right describes the Speed relationship between the steering torque...
Page 187 CH-86 CHASSIS - STEERING JSTEERING COLUMN 1. Tilt and Telescopic Steering Column D The manual tilt and telescopic mechanism mainly consists of a tilt lever, steering column tube, breakaway bracket, tilt lever lock bolt, and tilt steering stoppers. D The tilt lever controls the tilt and the telescope motion. D With the tilt adjustment range of 3.2_ (stepless) and the telescopic adjustment range of 40 mm (1.57 in.), the steering column can be adjusted to a position selected by the driver.
Page 188 CH-87 CHASSIS - STEERING 2. Energy Absorbing Mechanism Construction D The steering column has three energy absorbing mechanisms. D The intermediate shaft and the main shaft are joined by a serrated engagement of fine vertical teeth. Energy is absorbed by the contraction of the engagement. D The breakaway bracket is bolted to the instrument panel reinforcement via a capsule.
Page 189 CH-88 CHASSIS - STEERING JSTEERING LOCK SYSTEM D According with the use of the smart key system, a steering lock system which uses a lock/unlock motor to lock and unlock the steering wheel is used. This system mainly consists of the steering lock assembly, main body ECU, certification ECU and ID code box.
Page 190 EG-2 ENGINE - 2AZ-FXE ENGINE ENGINE 2AZ-FXE ENGINE JDESCRIPTION D The ’07 Camry Hybrid model uses the 2AZ-FXE engine that has been newly developed for hybrid system application. Based on the 2AZ-FE engine, the high-expansion ratio Atkinson cycle is used. It is an in-line 4-cylinder, 2.4-liter, 16-valve DOHC engine.
Page 191 EG-3 ENGINE - 2AZ-FXE ENGINE " Engine Specifications ’07 Camry 07 Camry ’07 Camry 07 Camry Model Model ’07 Camry Hybrid Model ’07 Camry Hybrid Model (For California) (Except California) Engine Type 2AZ-FXE 2AZ-FE No. of Cyls. & Arrangement 4-Cylinder, In-line 16-Valve DOHC, Chain Drive Valve Mechanism (with VVT-i)
Page 192 EG-4 ENGINE - 2AZ-FXE ENGINE JMAJOR DIFFERENCE The major differences between the 2AZ-FXE engine on the ’07 Camry Hybrid model and the 2AZ-FE engine on the ’07 Camry (except California package model) are as follows: System Features Engine Proper The piston shape has been changed. D The intake valve close timing has been retarded.
Page 193 Valve Valve Mechanism A timing chain and chain tensioner are used. The engine coolant is used the TOYOTA Genuine Cooling System SLLC (Super Long Life Coolant). The link-less type throttle body is used. The intake manifold made of plastic is used.
Page 194 EG-6 ENGINE - 2AZ-FXE ENGINE JENGINE PROPER 1. Cylinder Head Cover D A lightweight magnesium alloy diecast cylinder head cover used. D The cylinder head cover gasket and the spark plug gasket have been integrated to reduce the number of parts.
Page 195 EG-7 ENGINE - 2AZ-FXE ENGINE 3. Cylinder Head D The taper squish combustion chamber is used to realize the engine’s knocking resistance and fuel efficiency. D An upright intake port has been used to achieve a highly efficient intake. D Installing the injectors in the cylinder head enables the injectors to inject fuel as close as possible to the combustion chamber.
Page 196 EG-8 ENGINE - 2AZ-FXE ENGINE 4. Cylinder Block D Lightweight aluminum alloy is used for the cylinder block. D By producing the thin cast-iron liners and cylinder block as a unit, compaction is realized. D Air passage holes are provided in the crankshaft bearing area of the cylinder block. As a result, the air at the bottom of the cylinder flows smoother, and pumping loss (back pressure at the bottom of the piston generated by the piston’s reciprocal movement) is reduced to improve the engine’s output.
Page 197 EG-9 ENGINE - 2AZ-FXE ENGINE D The liners are the spiny-type which have been manufactured so that their casting exteriors form large irregular surfaces in order to enhance the adhesion between the liners and the aluminum cylinder block. The enhanced adhesion helps heat dissipation, resulting in a lower overall temperature and heat deformation of the cylinder bores.
Page 198 EG-10 ENGINE - 2AZ-FXE ENGINE 5. Piston D The piston shape has been changed from that of the ’07 Camry with 2AZ-FE engine to increase the compression ratio (9.8 ! 12.5) and achieve the high-expansion ratio Atkinson cycle. D The piston is made of aluminum alloy and the skirt area is compact and lightweight. D The piston head portion has a taper squish shape.
Page 199 EG-11 ENGINE - 2AZ-FXE ENGINE 7. Crankshaft D The crankshaft has 5 journals and 8 balance weights. D The precision and surface roughness of the pins and journals have been realized to reduce friction. D The balance shaft drive gear has been installed onto the crankshaft. D The crankshaft is made of forged steel.
Page 200 EG-12 ENGINE - 2AZ-FXE ENGINE JVALVE MECHANISM 1. General D The 2AZ-FXE engine is a high-expansion ratio Atkinson cycle engine of which the intake valve close timing has been significantly retarded by setting the VVT-i controller and intake camshaft to the retard side.
Page 201 EG-13 ENGINE - 2AZ-FXE ENGINE 2. Camshaft D The intake cam profile has been changed in conjunction with the change in valve timing. The new camshaft is adopted to realize excellent fuel economy, engine performance and reduce exhaust emissions. D The intake camshaft is provided with timing rotor to trigger the camshaft position sensor. D In conjunction with the adoption of the VVT-i system, an oil passage is provided in the intake camshaft in order to supply engine oil pressure to the VVT-i system.
Page 202 EG-14 ENGINE - 2AZ-FXE ENGINE 3. Intake and Exhaust Valve D Intake and exhaust valves with large-diameter valve face have been adopted to improve the intake air and exhaust gas flow. D Narrow valve stems are used to reduce the intake and exhaust resistance and for weight reduction. Camshaft Valve Lifter 208EG69...
Page 203 EG-15 ENGINE - 2AZ-FXE ENGINE 4. Timing Chain D A roller chain with an 8 mm (0.315 in.) pitch is used. D The timing chain is lubricated by an oil jet. Chain Tensioner Chain Damper Chain Slipper Oil Jet 181EG13 5.
Page 204 EG-16 ENGINE - 2AZ-FXE ENGINE JLUBRICATION SYSTEM 1. General D The lubrication circuit is fully pressurized and oil passes through an oil filter. D The trochoidal type oil pump is chain-driven by the crankshaft. D The oil filter is attached downward from the crankcase to improve serviceability. D Along with the adoption of the VVT-i system, the cylinder head is provided with a VVT-i controller and a camshaft timing oil control valve.
Page 205 EG-17 ENGINE - 2AZ-FXE ENGINE " Specifications liters (US qts, Imp. qts) 5.0 (5.3, 4.4) with Oil Filter liters (US qts, Imp. qts) 4.3 (4.5, 3.8) Oil Capacity without Oil Filter liters (US qts, Imp. qts) 4.1 (4.3, 3.6) 2. Oil Pump D The trochoidal type oil pump is chain-driven by the crankshaft, and fits compactly inside the oil pan.
Page 206 In addition, a bypass passage is incorporated into the cylinder head and the cylinder block. D Warm water from the engine is sent to the throttle body to prevent freeze-up. D TOYOTA Genuine SLLC (Super Long Life Coolant) is used to extend the maintenance interval. Throttle Body...
Page 207 EG-19 ENGINE - 2AZ-FXE ENGINE 2. Engine Coolant D TOYOTA genuine SLLC (Super Long Life Coolant) is used. Maintenance intervals are as shown in the table below: Type TOYOTA Genuine SLLC or the equivalent* Maintenance First Time 100,000 miles (160,000 km)
Page 208 EG-20 ENGINE - 2AZ-FXE ENGINE JINTAKE AND EXHAUST SYSTEM 1. General D A linkless type throttle body, which realizes excellent throttle control, is used. D The intake manifold is made of plastic to reduce the weight and the amount of heat transferred from the cylinder head.
Page 209 EG-21 ENGINE - 2AZ-FXE ENGINE 2. Air Cleaner D A nonwoven, full-fabric type air cleaner element is used. D A carbon filter, which adsorbs the HC that accumulates in the intake system when the engine is stopped, is used in the air cleaner cap in order to reduce evaporative emissions. This filter is maintenance-free. D Resonators have been provided to reduce the amount of intake air sound.
Page 210 EG-22 ENGINE - 2AZ-FXE ENGINE 4. Intake Manifold D The intake manifold is made of plastic to reduce the weight and the amount of heat transferred from the cylinder head. As a result, it has become possible to reduce the intake air temperature and improve the intake volumetric efficiency.
Page 211 EG-23 ENGINE - 2AZ-FXE ENGINE 6. Exhaust Pipe General D 2-way exhaust control system is provided to reduce noise and vibration in the main muffler. D A long tail mechanism is used in the main muffler to aim at reducing exhaust noise while the engine is running in the low speed range.
Page 212 EG-24 ENGINE - 2AZ-FXE ENGINE 2-Way Exhaust Control System D 2-way exhaust control system is used. This system reduces the back pressure by opening and closing a variable valve that is enclosed in the main muffler, thus varying the exhaust gas pressure. D The valve opens steplessly in accordance with the operating condition of the engine, thus enabling a quieter operation at lower engine speeds, and reducing back pressure at higher engine speeds.
Page 213 EG-25 ENGINE - 2AZ-FXE ENGINE JFUEL SYSTEM 1. General D A fuel returnless system is used to reduce evaporative emissions. D A fuel cut control is used to stop the fuel pump when the SRS airbag is deployed in a frontal or side collision.
Page 214 EG-26 ENGINE - 2AZ-FXE ENGINE 2. Fuel Returnless System The fuel returnless system is used to reduce the evaporative emission. As shown below, integrating the fuel filter, pressure regulator, and fuel sender gauge with fuel pump assembly makes it possible to discontinue the return of fuel from the engine area and prevent temperature rise inside the fuel tank.
Page 215 EG-27 ENGINE - 2AZ-FXE ENGINE 4. Fuel Tank The fuel tank made of 1.8 mm (0.07 in.) thick steel sheet, which provides higher pressure resistance is used. 02HEG15Y...
Page 216 EG-28 ENGINE - 2AZ-FXE ENGINE JIGNITION SYSTEM 1. General A DIS (Direct Ignition System) is used. The DIS improves the ignition timing accuracy, reduces high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS in this engine is an independent ignition system, which has one ignition coil (with igniter) for each cylinder.
Page 217 EG-29 ENGINE - 2AZ-FXE ENGINE 4. Layout of Main Components Fuel Vapor-Containment Valve Canister Pump Module Purge VSV Canister THS ECU Filler Door Courtesy Switch Fuel Filler Door Opener Fuel Tank Pressure Sensor Fuel Pump Multi-information Display Malfunction Indicator Lamp Mass Air Flow Meter Master Warning Light Stop Light Switch...
Page 218 EG-29 ENGINE - 2AZ-FXE ENGINE JENGINE CONTROL SYSTEM 1. General D The 2AZ-FXE engine is controlled by the THS ECU. The THS ECU determines the motive force required by the driver in accordance with the pedal effort applied by the driver on the accelerator. Then, the THS ECU determines the driving conditions of the vehicle in accordance with the vehicle speed, vehicle load, and various sensor signals.
Page 219 EG-30 ENGINE - 2AZ-FXE ENGINE System Outline D A control system that functions as follows is used: When the engine is stopped while the vehicle is in motion or stopped, the fuel vapor-containment valve keeps the fuel tank sealed to prevent the fuel vapor from being discharged.
Page 220 EG-31 ENGINE - 2AZ-FXE ENGINE 2. Construction The configuration of the engine control system is as shown in the following chart. MASS AIR FLOW METER INTAKE AIR TEMP. SENSOR No.1 Injector No.2 Injector ENGINE COOLANT No.3 Injector TEMP. SENSOR No.4 Injector THROTTLE POSITION SENSOR VTA2...
Page 221 EG-32 ENGINE - 2AZ-FXE ENGINE OXYGEN SENSOR ID CODE BOX HEATER CONTROL AIR FUEL RATIO SENSOR HA1A Bank 1, Sensor 1 IGSW IG2 RELAY OXYGEN SENSOR HT1B Bank 1, Sensor 2 BATT COOLING FAN CONTROL BATTERY FANL Cooling Fan Relays FANH THS ECU DATA LINK CONNECTOR 3...
Page 222 EG-33 ENGINE - 2AZ-FXE ENGINE 3. Engine Control System Diagram : CAN (CAN No.1 Bus) Airbag Sensor Meter ECU A / C ECU EPS ECU Assembly IG2 Relay Battery Skid Control IGCT Relay Fuel Vapor-containment Valve Audio Head DLC 3 Unit* Cooing Fan Relays Canister Pump...
Page 223 EG-35 ENGINE - 2AZ-FXE ENGINE 5. Main Component of Engine Control System General The main components of the 2AZ-FXE engine control system are as follows: Components Outline Quantity Function The THS ECU optimally controls the SFI, ESA and ISC to suit the operating THS ECU 32-bit CPU conditions of the engine in accordance...
Page 224 EG-36 ENGINE - 2AZ-FXE ENGINE Mass Air Flow Meter D This mass air flow meter, which is a plug-in type, allows a portion of the intake air to flow through the detection area. By directly measuring the mass and the flow rate of the intake air, the detection precision is improved and the intake air resistance is reduced.
Page 225 EG-37 ENGINE - 2AZ-FXE ENGINE Camshaft Position Sensor The camshaft position sensor is mounted on the left bank of cylinder head. To detect the camshaft position, a protrusion that is provided on the timing pulley is used to generate 1 pulse for every 2 revolution of the crankshaft.
Page 226 EG-38 ENGINE - 2AZ-FXE ENGINE Throttle Position Sensor D The no-contact type throttle position sensor uses a Hall IC, which is mounted on the throttle body. D The Hall IC is surrounded by a magnetic yoke. The Hall IC converts the changes that occur in the magnetic flux at that time into electrical signals and outputs them in the form of a throttle valve effort to the THS ECU.
Page 227 EG-39 ENGINE - 2AZ-FXE ENGINE Knock Sensor (Flat Type) 1) General In the conventional type knock sensor (resonant type), a vibration plate, which has the same resonance point as the knocking frequency of the engine, is built in and can detect the vibration in this frequency band.
Page 228 EG-40 ENGINE - 2AZ-FXE ENGINE 3) Operation The knocking vibration is transmitted to the steel weight and its inertia applies pressure to Steel Weight piezoelectric element. The action Inertia generates electromotive force. Piezoelectric Element 214CE08 4) Open/Short Circuit Detection Resistor During the power source is IG-ON, the open/short circuit detection resistor in the knock sensor and the resistor in the THS ECU keep the voltage at the terminal KNK1 of engine constant.
Page 229 EG-41 ENGINE - 2AZ-FXE ENGINE Heated Oxygen Sensor and Air Fuel Ratio Sensor 1) General D The heated oxygen sensor and the air fuel ratio sensor differ in output characteristics. D The output voltage of the heated oxygen sensor changes in accordance with the oxygen concentration in the exhaust gas.
Page 230 EG-42 ENGINE - 2AZ-FXE ENGINE 2) Construction D The basic construction of the heated oxygen sensor and the air-fuel ratio sensor is the same. However, they are divided into the cup type and the planar type, according to the different types of heater construction that are used.
Page 231 EG-43 ENGINE - 2AZ-FXE ENGINE 6. ETCS-i (Electronic Throttle Control System-intelligent) General D In the conventional throttle body, the throttle valve angle is determined invariably by the amount of the accelerator pedal effort. In contrast, ETCS-i uses the THS ECU to calculate the optimal throttle valve angle that is appropriate for the respective driving condition and uses a throttle control motor to control the angle.
Page 232 EG-44 ENGINE - 2AZ-FXE ENGINE Control 1) General The ETCS-i consists of the following four functions: D ISC (Idle Speed Control) D TRAC (Traction Control) D VSC (Vehicle Stability Control) D Cruise Control 2) Idle Speed Control The THS ECU controls the throttle valve in order to constantly maintain an ideal idle speed. 3) TRAC Throttle Control As part of the TRAC function, the throttle valve is closed by a demand signal from the skid control ECU if an excessive amount of slippage is created at a driving wheel, thus facilitating the vehicle in ensuring...
Page 233 EG-45 ENGINE - 2AZ-FXE ENGINE 7. VVT-i (Variable Valve Timing-intelligent) System General D The VVT-i system is designed to control the intake camshaft within a range of 30_ (of Crankshaft Angle) to provide valve timing that is optimally suited to the engine condition. This improves torque in all the speed ranges as well as increasing fuel economy, and reducing exhaust emissions.
Page 234 EG-46 ENGINE - 2AZ-FXE ENGINE Effectiveness of the VVT-i System Operation State Objective Effect Latest Timing D During D Stabilized idling rpm Idling Minimizing overlap to prevent D At Light D Better fuel economy blow back to the intake side Load 02HEG04TE to Advance Side...
Page 235 EG-47 ENGINE - 2AZ-FXE ENGINE Construction 1) VVT-i Controller D This controller consists of the housing driven from the timing chain and the vane coupled with the intake camshaft. D The oil pressure sent from the advance or retard side path at the intake camshaft causes rotation in the VVT-i controller vane circumferential direction to vary the intake valve timing continuously.
Page 236 EG-48 ENGINE - 2AZ-FXE ENGINE Operation 1) Advance When the camshaft timing oil control valve is positioned as illustrated below by the advance signal from the THS ECU, the resultant oil pressure is applied to the timing advance side vane chamber to rotate the camshaft in the timing advance direction.
Page 237 EG-49 ENGINE - 2AZ-FXE ENGINE 8. Fuel Pump Control A fuel cut control is used to stop the fuel pump once when any of the SRS airbags is deployed. In this system, the airbag deployment signal from the airbag sensor assembly is detected by the THS ECU, and it turns OFF the circuit opening relay.
Page 238 EG-50 ENGINE - 2AZ-FXE ENGINE 9. Cooling Fan Control System D A cooling fan control system in which the THS ECU controls the cooling fan speed in accordance with the engine coolant temperature, inverter water temperature and the air conditioning operating condition. D The THS ECU controls the cooling fan speed based on A/C pressure sensor signal, inverter water temperature signal and engine coolant temperature sensor signals.
Page 239 EG-51 ENGINE - 2AZ-FXE ENGINE 10. Evaporative Emission Control System General D The evaporative emission control system on the ’07 Camry Hybrid model consists of the fuel vapor-containment system (to prevent fuel vapor escaping into the atmosphere), the purge flow control (to purge fuel vapor), and the EVAP leak check (to check for leakage from the evaporative emission control system).
Page 240 EG-52 ENGINE - 2AZ-FXE ENGINE " System Diagram Fuel Filler Door Switch Multi Information Display Fuel Filler Door Opener Fuel Vapor- Containment Valve Fuel Outlet Valve To Intake Fuel Tank Manifold Pressure Sensor Purge Filler Door Fuel Tank Canister Courtesy Pump Module Switch Purge Line...
Page 241 EG-53 ENGINE - 2AZ-FXE ENGINE Function of Main Components Operation Component Function Fuel Tank Detects the internal pressure of the fuel tank and sends a Pressure Sensor signal to the THS ECU. Fuel Opens or closes in accordance with a signal provided by the Vapor-Containment THS ECU, in order to seal the fuel tank or release its internal Valve...
Page 242 EG-54 ENGINE - 2AZ-FXE ENGINE Construction and Operation 1) Fuel Vapor-Containment Valve D Installed between the fuel tank and the canister, the fuel vapor-containment valve consists of a solenoid valve that turns ON/OFF to seal the fuel tank or release its internal pressure. This valve is normally closed.
Page 243 EG-55 ENGINE - 2AZ-FXE ENGINE 2) Fuel Filler Door Opener D The fuel filler door opener consists of an electric motor, worm gear, fuel filler door lock gear, and fuel filler door lock shaft. D The rotational movement of the electric motor is converted into a sliding movement of the fuel filler door lock shaft by the worm gear and the fuel filler door lock gear.
Page 244 EG-56 ENGINE - 2AZ-FXE ENGINE 3) Filler Door Courtesy Switch The fuel filler door courtesy switch, which is mounted on the inside of the fuel filler door, determines whether the fuel filler door is open or closed by way of the ON (open) or OFF (closed) state of the switch. Filler Door Courtesy Switch 02HEG25Z...
Page 245 EG-57 ENGINE - 2AZ-FXE ENGINE 4) Multi-information Display D In this system, if the internal pressure of the fuel tank is high before the fuel filler door is opened by turning the fuel filler door switch ON, the THS ECU opens the fuel vapor-containment valve to release the fuel vapor.
Page 246 EG-58 ENGINE - 2AZ-FXE ENGINE 5) Canister D The canister absorbs the fuel vapor during refueling standby or purge flow control. D In addition to the conventional canister construction, this canister contains a purge buffer, which uses highly concentrated activated charcoal, in front of the purge side port. The function of the purge buffer is to moderate the concentrated fuel vapor that is discharged from the fuel tank when the fuel vapor-containment valve is open.
Page 247 EG-59 ENGINE - 2AZ-FXE ENGINE 6) Canister Pump Module D The canister pump module is used for checking the fuel pipe, canister, and fuel tank for leakage, and for checking the functions of the parts. D Canister pump module consists of the vent valve, canister pressure sensor, leak detection pump, and pump motor.
Page 248 EG-60 ENGINE - 2AZ-FXE ENGINE System Operation 1) Fuel Vapor-containment System a. Parked (Power Source Mode OFF) The THS ECU seals the fuel vapor in the fuel tank by closing the fuel vapor-containment valve. If, at this time, the internal pressure of the fuel tank increases to a level that activates the fuel outlet valve located in the fuel vapor-containment valve, the fuel outlet valve opens to release the internal pressure of the fuel tank.
Page 249 EG-61 ENGINE - 2AZ-FXE ENGINE c. Refueling Ready D When the internal pressure of the fuel tank decreases to a level close to the atmospheric pressure, the THS ECU opens the fuel filler door. At this time, the multi-information display will show the “REFUEL READY”.
Page 250 EG-62 ENGINE - 2AZ-FXE ENGINE d. Fuel Filler Door Open Warning If one of the conditions listed below has been met while the fuel filler door is open, the THS ECU will show a “CLOSE FUEL LID” warning message on the multi-information display to warn the driver. D The vehicle speed is higher than 50km/h (31 mph) and the vehicle has traveled more than 1 km (0.6 miles).
Page 251 EG-63 ENGINE - 2AZ-FXE ENGINE 2) Purge Flow Control a. General D When the engine has satisfied predetermined conditions (closed loop, engine coolant temp. above 70_C [162_F], etc), stored fuel vapor is purged in the canister whenever the purge VSV is opened by the THS ECU.
Page 252 EG-64 ENGINE - 2AZ-FXE ENGINE c. Fuel Tank Internal Pressure is High If the internal pressure in the fuel tank is high and the purge VSV is open, the THS ECU opens the fuel vapor-containment valve in order to release the pressure from the fuel tank. At this time, the fuel vapor that is absorbed in the canister is drawn inside the engine by intake vacuum and burned.
Page 253 EG-65 ENGINE - 2AZ-FXE ENGINE 3) EVAP Leak Check a. General D The following are the typical conditions for enabling an EVAP leak check: D 5 hour have elapsed after the engine has been turned OFF.* D Altitude: Below 2400 m (8000 feet) D Auxiliary Battery Voltage: 10.5 V or more Typical Enabling Condition D Power Source Mode: OFF...
Page 254 EG-66 ENGINE - 2AZ-FXE ENGINE " Fuel Tank Internal Pressure Equals Atmospheric Pressure Vent Valve (Vent / Close) Leak Detection Pump (ON / OFF) Purge VSV (Open / Close) Fuel Vapor-containment Valve (Open / Close) Fuel Tank Pressure Sensor Atmospheric Pressure (0 kPa) Canister Pressure Sensor at Leak Detection Pump 02HEG35Y...
Page 255 EG-67 ENGINE - 2AZ-FXE ENGINE " Fuel Tank Internal Pressure High or Low Vent Valve (Vent / Close) Leak Detection Pump (ON / OFF) Purge VSV (Open / Close) Fuel Vapor-containment Valve (Open / Close) Fuel Tank Pressure Sensor Atmospheric Pressure (0 kPa) Fuel Tank Pressure Sensor Atmospheric Pressure (0 kPa) Canister Pressure Sensor...
Page 256 EG-68 ENGINE - 2AZ-FXE ENGINE b. Atmospheric Pressure Measurement 1) When the power source mode is selected to OFF, the purge VSV and the fuel vapor-containment valve are OFF (close). Therefore, the atmospheric pressure is introduced into the canister. 2) The THS ECU measures the atmospheric pressure through the signals provided by the canister pressure sensor.
Page 257 EG-69 ENGINE - 2AZ-FXE ENGINE c. 0.02 in. Leak Pressure Measurement 1) The THS ECU turns OFF (vent) the vent valve, introduces atmospheric pressure into the canister, and actuates the leak detection pump, in order to create a negative pressure. 2) At this time, the pressure will not decrease beyond a predetermined level due to the atmospheric pressure that enters through a 0.02 in orifice.
Page 258 EG-70 ENGINE - 2AZ-FXE ENGINE d. Canister Leak Check 1) During the leak detection pump actuation, the THS ECU turns ON (close) the vent valve in order to introduce a vacuum into the canister. 2) When the pressure in the system stabilizes, the THS ECU compares this pressure with the 0.02 in. pressure in order to check for a leakage.
Page 259 EG-71 ENGINE - 2AZ-FXE ENGINE " Fuel Tank Internal Pressure Equals Atmospheric Pressure Vent Valve (Close) Leak Detection Pump (ON) Purge VSV (Close) Fuel Vapor-containment Valve (Close) Fuel Tank Pressure Sensor Fuel Vapor-containment Valve (Stuck Opened) P2450 P1421 Atmospheric Pressure (0 kPa) Canister Pressure Sensor at Leak Detection Pump P1420...
Page 260 EG-72 ENGINE - 2AZ-FXE ENGINE e. Purge VSV Monitor 1) After completing an EVAP leak check, the THS ECU turns ON (open) the purge VSV with the leak detection pump actuated, and introduces the atmospheric pressure in the intake manifold. 2) If the pressure change at this time is within the normal range, the THS ECU determines the condition to be normal.
Page 261 EG-73 ENGINE - 2AZ-FXE ENGINE f. Fuel Vapor-Containment Valve Stuck Closed Judgment and Fuel Tank Leak Check i) Fuel Tank Internal Pressure Equals Atmospheric Pressure 1) The THS ECU actuates the leak detection pump, and turns ON the canister pump module and the fuel vapor-containment valve (open), in order to introduce a vacuum into the fuel tank, pipe, and canister.
Page 262 EG-74 ENGINE - 2AZ-FXE ENGINE ii) Fuel Tank Internal Pressure is Higher or Lower than Atmospheric Pressure If the internal pressure in the fuel tank is high or low, the THS ECU determines that there is no leakage in the fuel tank. Thus, it only determines that the fuel vapor-containment valve is stuck closed, without performing a fuel tank leakage check.
Page 263 BE-2 BODY ELECTRICAL - MULTIPLEX COMMUNICATION BODY ELECTRICAL MULTIPLEX COMMUNICATION JDESCRIPTION D The multiplex communication system of the ’07 Camry Hybrid model uses the 2 communication protocols described below in order to achieve a streamlined wiring harness configuration. - CAN (Controller Area Network): Classified into two types according to communication speed, the HS (High Speed)-CAN is used for the power train, chassis and body electrical systems, and the MS (Medium Speed)-CAN is used for the body electrical system.
Page 264 BE-3 BODY ELECTRICAL - MULTIPLEX COMMUNICATION — REFERENCE — MPX communication uses serial communication data that consists of bits and frames in order to exchange information among the various ECUs. This allows a reduction of the amount of wiring on the vehicle. D A bit is the basic unit of communication that is used to represent the information.
Page 265 *: The BEAN is used in the body electrical system of the ’06 Camry and some other TOYOTA models, but is not used on the ’07 Camry Hybrid model.
Page 266 A twisted-pair wire is used for CAN and AVC-LAN communication. A single, AV (Automobile Vinyl) wire is used for BEAN* communication. *: The BEAN is used in the body electrical system of the ’06 Camry and some other TOYOTA models, but is not used on the ’07 Camry Hybrid model.
Page 267 BE-6 BODY ELECTRICAL - MULTIPLEX COMMUNICATION JCAN 1. General D The ’07 Camry Hybrid model uses two types of CAN that have different communication speeds: HS-CAN (500 kbps) and MS-CAN (250 kbps). D The HS-CAN consists of the CAN No.1 bus. The terminating resistors of the CAN No.1 bus are built into the THS ECU and meter ECU.
Page 268 BE-7 BODY ELECTRICAL - MULTIPLEX COMMUNICATION " CAN No.1 Bus to/from MS Bus Junction Main Body THS ECU Connector (Front LH) A/C ECU Meter ECU EPS ECU Junction Junction Connector Audio Head Connector (Front Unit* (Front Center) Yaw Rate & Airbag Sensor Deceleration Assembly...
Page 269 BE-8 BODY ELECTRICAL - MULTIPLEX COMMUNICATION 2. Layout of Main Components Audio Head Unit* Certification ECU Skid Control ECU Junction Connector A/C ECU (Front Center) Junction Connector Combination Meter (Front RH) D Meter ECU Option Connector* Junction Connector (Front LH) Main Body ECU Yaw Rate &...
Page 270 BE-9 BODY ELECTRICAL - MULTIPLEX COMMUNICATION 3. Diagnosis D If a malfunction occurs on the CAN communication line, the ECU that is connected to the CAN communication line stores the DTC (Diagnostic Trouble Code) in its memory. D The 5-digit DTC can be read by connecting a hand-held tester to the DLC3. D The DLC3 is equipped with CAN-H and CAN-L terminals for CAN diagnosis.
Page 271 BE-10 BODY ELECTRICAL - MULTIPLEX COMMUNICATION JAVC-LAN 1. General The AVC-LAN is used to transmit data only between the audio head unit and the stereo amplifier. " System Diagram Stereo Amplifier Audio Head Unit 025BE06P 2. Layout of Main Components Audio Head Unit Stereo Amplifier 025BE05TE...
Page 272 BE-11 BODY ELECTRICAL - MULTIPLEX COMMUNICATION JCUSTOMIZED BODY ELECTRONICS SYSTEM A hand-held tester can be used to customize the system settings. Hand-Held Tester Default Available System Contents Display Content Setting Setting 1 TIME/ TRUNK LID OPER To change the operation method of 2 TIMES/ (Trunk lid open 0.8s PR...
Page 273 BE-12 BODY ELECTRICAL - MULTIPLEX COMMUNICATION Hand-Held Tester Default Available System Contents Display Content Setting Setting Function to change the lighting time 7.5 sec/ LIGHTING TIME after closing the door. (It will quickly 15 sec 15 sec/ (Lighting time) fade out in the event the power source 30 sec is turned ON.) Function to light up the interior lights...
Page 274 BE-13 BODY ELECTRICAL - MULTIPLEX COMMUNICATION Hand-Held Tester Default Available System Contents Display Content Setting Setting +2_C/ SET TEMP SHIFT +1_C/ To control with the shifted temperature (Set Temperature NORMAL NORMAL/ against the display temperature. Shift) - 1_C/ - 2_C In case of turning the A/C ON when you desire to make the compartment AIR INLET MODE...
Page 275 BE-14 BODY ELECTRICAL - POWER DISTRIBUTOR POWER DISTRIBUTOR JDESCRIPTION D The power distributor is built into the engine room relay block, and uses a small mechanical relay and semiconductor relay for a compact and lightweight design. D The power distributor has a headlight control function. This function dims the headlights (Hi beam) in accordance with operation signals from the main body ECU while the daytime running light system is operating.
Page 276 BE-15 BODY ELECTRICAL - LIGHTING LIGHTING JDESCRIPTION 1. General The lighting system includes the following equipment: Item Equipment Headlight Halogen Standard Daytime Running Light Standard Automatic Light Control System Standard Illuminated Entry Standard Light Turn-OFF System (With Delay Function) Standard 2.
Page 277 BE-16 BODY ELECTRICAL - LIGHTING 3. Rear Exterior Light Turn Signal Light High Mount Stop Light Back-up Light License Plate Lights Rear Side Marker Light Taillight and Stop Light 02HBE05TE " Specifications Light Type Taillight and Stop Light LED x 9 0.2/4.1 Rear Side Marker Light LED x 2...
Page 278 BE-17 BODY ELECTRICAL - LIGHTING JDAYTIME RUNNING LIGHT SYSTEM D A daytime running light system is designed to automatically illuminate the headlights (dimmed Hi beam), during the daytime to keep the car highly visible to other vehicles. D The main body ECU and power distributor control this system. The main body ECU transmits a turn ON signal to the power distributor, and the power distributor illuminates and dims the Hi beam with the duty control.
Page 279 BE-18 BODY ELECTRICAL - LIGHTING JILLUMINATED ENTRY SYSTEM 1. General D The illuminated entry system of the ’07 Camry Hybrid model controls interior light and power switch illumination. D The interior light is operated when the light switch is in the DOOR position. "...
Page 280 BE-19 BODY ELECTRICAL - LIGHTING 2. Layout of Main Components Door Lock Assembly D Door Position Switches Door Courtesy Switch Interior Light* Door Lock Assembly D Door Position Switch Door Courtesy Switches Door Courtesy Switch Interior Light* Light Switch* Overhead Console Certification ECU Power Switch Main Body ECU...
Page 281 BE-20 BODY ELECTRICAL - LIGHTING 3. Interior Light Control D The interior light control (interior light and power switch illumination) consists primarily of the fade-in/fade-out function and timer illumination function. D The interior light control activates as described in the diagram below when one of items is in the respective state.
Page 282 BE-21 BODY ELECTRICAL - LIGHTING JAUTOMATIC LIGHT CONTROL SYSTEM D When the light control switch is in the AUTO position, the automatic light control system detects ambient light levels and controls the headlights and taillights (parking lights, taillights and license plate lights). D The light control sensor detects the ambient light levels.
Page 283 BE-22 BODY ELECTRICAL - LIGHTING JLIGHT TURN-OFF SYSTEM D The light turn-off system is used to prevent the driver from leaving the vehicle with the exterior lights (headlights, parking lights, taillights and license plate lights) ON. D If the power source is turned OFF and any door is opened and all doors (including the luggage compartment door) are closed with all exterior lights ON, this system turns them OFF approximately 30 seconds after door closure.
Page 284 BE-23 BODY ELECTRICAL - METER METER JCOMBINATION METER 1. General D An optitron display type combination meter is used which realizes excellent visibility through the use of smoke acrylic in the protective panel, and bright LEDs (Light Emitting Diodes) that have high contrast to illuminate the indicator and the dial.
Page 285 BE-24 BODY ELECTRICAL - METER 2. System Diagram Steering Pad Switch Vehicle Speed Signal D THS ECU DISP Switch D Main Body ECU D Audio Head Unit D Stereo Amplifier D Tire Pressure Warning THS ECU System ECU* Warning Light Control Rheostat Signal Warning Display Control D Heater Control Panel...
Page 286 BE-25 BODY ELECTRICAL - METER " Input and output communication signals of the combination meter Protocol Input Signal Output Signal D Engine speed D Engine coolant temperature D Fuel injection volume D Shift position D Buzzer sounding request THS ECU Vehicle Speed D Diagnosis (Cruise) D READY and cruise MAIN indicator...
Page 287 BE-26 BODY ELECTRICAL - METER 3. Illumination Control D When the power source is switched to IG-ON, the illumination control operates as follows (1, 2): D When the power source is switched to OFF, the illumination control is as follows (3): 1) The needles of the fuel expense meter, speedometer, fuel gauge and engine coolant temperature gauge illuminate, and “HYBRID SYNERGY DRIVE”...
Page 288 BE-27 BODY ELECTRICAL - METER 4. Multi-information Display General The multi-information display has five modes: Mode Outline D Five types of information can be displayed: outside temperature, driving range, average fuel consumption since refueling, Cruise Information distance driven since THS II start, and average speed since THS (See page BE-29) II start.
Page 289 BE-28 BODY ELECTRICAL - METER Flow of The Multi-information Display Indication D The multi-information display mode can be changed as shown in the flow chart below: Display OFF Smart Key System Interrupts display even during warning mode. Warning: Occurs Fuel Lid REFUEL READY D Issues warning if lid is open.
Page 290 BE-29 BODY ELECTRICAL - METER D The cruise information, odo/tripmeter, energy monitor and eco drive level are displayed in the following order, changing each time the DISP switch is pressed. However, pressing the DISP switch for approximately 1 second or more changes the display to the outside temperature indication. Average Fuel Distance Driven Average Speed...
Page 291 BE-30 BODY ELECTRICAL - METER Eco Drive Level Display General D An eco drive level display is used, which changes the meter ring luminance and multi-information display in 4 levels, to indicate the average fuel consumption. This is calculated by the meter ECU, based on the fuel injection volume and the distance driven since the power source was turned to READY-ON.
Page 292 BE-31 BODY ELECTRICAL - METER Warning Mode 1) General D When a warning is necessary, the warning display interrupts the multi-information display. D The master warning light may illuminate or flash and the buzzer may sound depending on the item in the multi-information display.
Page 293 BE-32 BODY ELECTRICAL - METER Warning Detail Warning Detail Driver door is opened with Key is not inside vehicle. shift lever in any position : Flashes : Flashes other than P. Buzzer: Sounds Buzzer: Sounds 025BE19P 025BE20P Steering lock has not been Steering lock is released.
Page 294 BE-33 BODY ELECTRICAL - METER Warning Detail Warning Detail Engine oil pressure is low. Engine coolant temperature (Displayed while power is high. source is READY ON) : Flashes : Flashes Buzzer: Sounds Buzzer: Sounds 025BE30P 025BE31P Sliding roof is open and driver door is open.
Page 295 BE-34 BODY ELECTRICAL - METER Service Tip The accumulated vehicle driven distance is stored in the meter ECU and can be reset using the following procedure. 1) Switch the power source to IG-ON and make sure that the LCD of the multi-information display/TRIP A display is on.
Page 296 BE-35 BODY ELECTRICAL - METER 5. Buzzer General The table below shows the warning and reminder functions of the buzzer. Function Item Warning Multi-information Display Warning Mode Indication (See page BE-31) D Key Reminder (See page BE-115) Reminder D Seat Belt Reminder (See page BE-146) 6.
Page 297: Air Conditioning
BE-36 BODY ELECTRICAL - AIR CONDITIONING AIR CONDITIONING JDESCRIPTION D A ES27 type electric inverter compressor is used on the ’07 Camry Hybrid model. This compressor is driven by the alternating current that is supplied by the A/C inverter, which is integrated with the compressor.
Page 298 BE-37 BODY ELECTRICAL - AIR CONDITIONING JPERFORMANCE AND SPECIFICATION 1. Performance Heat Output 6000 Heater Air Flow Volume Power Consumption Maximum 210 Cooling Capacity 6100 Air Flow Volume Air Conditioning Power Consumption Maximum 260 2. Specification Type SFA (Straight Flow Aluminum) -II Size 201.5 x 150 x 27 Heater Core...
Page 299 BE-38 BODY ELECTRICAL - AIR CONDITIONING JSYSTEM DIAGRAM Air Mix Servo Motor Solar Sensor (For Driver) A/C Pressure Sensor Air Mix Servo Motor (For Front Passenger) Room Temp. Sensor Air Inlet Servo Motor Evaporator Temp. Sensor Air Vent Servo Motor A/C ECU Outside Temp.
Page 300 BE-39 BODY ELECTRICAL - AIR CONDITIONING JLAYOUT OF MAIN COMPONENTS A/C Pressure Sensor Electric Water Pump THS ECU Electric Inverter Compressor Condenser Outside Temp. Sensor Steering Pad Switch Solar Sensor A/C ECU Room Temp. Sensor A/C Unit Heater Control Panel ECO Switch 02HBE33TE...
Page 301 BE-40 BODY ELECTRICAL - AIR CONDITIONING Air Vent Mode Servo Motor Air Mix Servo Motor Air Inlet Servo Motor Evaporator (For Driver) Evaporator Temp. Sensor Heater Core Blower Motor PTC Heater Air Mix Servo Motor (For Front Passenger) A/C Unit 02HBE34TE...
Page 302 BE-41 BODY ELECTRICAL - AIR CONDITIONING JMODE POSITION AND DAMPER OPERATION Center Defroster To Driver Side To Passenger Side Side Defroster Side Defroster Fresh Air Recirc. Air Blower Motor Evaporator Heater Core Side Register Side Register Front Center Register Front Footwell Front Footwell Rear Center Register Register Duct...
Page 303 BE-42 BODY ELECTRICAL - AIR CONDITIONING JAIR OUTLETS AND AIRFLOW VOLUME 025BE43TE FACE FOOT SELECTION INDICATION MODE SIDE SIDE AUTO MANUAL FACE B/ L-U* B/ L-L* FOOT-F* FOOT-R* FOOT-D* F / D 02HBE36TE The size of the circle f indicates the proportion of airflow volume. : Greater airflow volume at the upper area.
Page 304 BE-43 BODY ELECTRICAL - AIR CONDITIONING JCONSTRUCTION AND OPERATION 1. Heater Control Panel and Steering Pad Switch D The air conditioning status is displayed on an LCD (Liquid Crystal Display) panel. D Some of A/C operations (AUTO operation, A/C OFF and driver side temperature setting) can be performed using the steering pad switches (AUTO, OFF and TEMP) on the steering wheel.
Page 305 BE-44 BODY ELECTRICAL - AIR CONDITIONING 2. Air Conditioning Unit General A semi-center location air conditioning unit, in which the evaporator and heater core are placed in the vehicle’s longitudinal direction, is used. As a result, the air conditioning unit has been made compact and lightweight.
Page 306 BE-45 BODY ELECTRICAL - AIR CONDITIONING PTC Heater D The PTC heater is located above the heater core in the air conditioning unit. D The PTC heater consists of a PTC element, aluminum fin, and brass plate. When current is applied to the PTC element, it generates that to warm the air that passes through the unit.
Page 307 BE-46 BODY ELECTRICAL - AIR CONDITIONING Evaporator A semi-center location air conditioning unit, in which the evaporator and heater core are placed in the vehicle’s longitudinal direction, is used. As a result, the air conditioning unit has been made compact and lightweight.
Page 308 BE-47 BODY ELECTRICAL - AIR CONDITIONING BUS connector D A BUS connector is used in the wire harness connection that connects the servo motor from the A/C ECU. BUS Connector BUS Connector To A/C ECU To Air Mix Servo To Air Inlet Motor (For Driver) Servo Motor BUS Connector...
Page 309 BE-48 BODY ELECTRICAL - AIR CONDITIONING Servo Motor The pulse pattern type servo motor consists of a printed circuit board and servo motor. The printed circuit board has three contact points, and transmits to the A/C ECU two ON-OFF signals for the difference of the pulse phase.
Page 310 BE-49 BODY ELECTRICAL - AIR CONDITIONING Clean Air Filter A pollen removal type filter is used. This filter excels in the removal of dust and pollen. The filter is made of polyester. Thus, it can be disposed of easily as a non hazardous combustible material, a feature that is provided in consideration of the environment.
Page 311 BE-50 BODY ELECTRICAL - AIR CONDITIONING 3. Condenser D A MF (Multi-Flow) type condenser is used. The condenser consists of two cooling portions: a condensing portion and a super-cooling portion, and gas-liquid separator (modulator) are integrated together. This condenser uses a sub-cool cycle that offers excellent heat-exchange performance. D In the sub-cool cycle, after the refrigerant passes through the condensing portion of the condenser, both the liquid refrigerant and the gaseous refrigerant that could not be liquefied are cooled again in the super-cooling portion.
Page 312 BE-51 BODY ELECTRICAL - AIR CONDITIONING 4. A/C Compressor General D Along with the installation of the hybrid unit on the ’07 Camry Hybrid model, an ES27 electric inverter compressor that is driven by a motor is used. The basic construction and operation of this compressor are the same as the ordinary scroll compressor, except that it is driven by an electric motor.
Page 313 BE-52 BODY ELECTRICAL - AIR CONDITIONING Construction D The electric inverter compressor consists of a spirally wound fixed scroll and variable scroll that form a pair, a brushless motor, an oil separator, a motor shaft and A/C inverter. D The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the variable scroll to revolve while maintaining the same posture, the volume of the space that is partitioned by both scrolls varies to perform the suction, compression, and the discharge of the refrigerant gas.
Page 314 BE-53 BODY ELECTRICAL - AIR CONDITIONING Operation 1) Suction As the capacity of the compression chamber, which is created between the variable scroll and the fixed scroll, increases in accordance with the revolution of the variable scroll, refrigerant gas is drawn in from the intake port.
Page 315 BE-54 BODY ELECTRICAL - AIR CONDITIONING 5. Electric Water Pump D The ’07 Camry Hybrid model uses an electric water pump for air conditioning. This provides a stable heater performance even if the engine is stopped because of a function of the THS-II. D The ’07 Camry Hybrid model uses a new type of electrical water pump in which the water flow resistance has been reduced.
Page 316 Therefore, if the Plasmacluster generator requires repairs, be sure to have them done at a Toyota dealer. D Do not apply any type of spray (such as a cleaning solvent or hair spray) or stick any foreign matter into the Plasmacluster ion outlet, as this could cause improper operation or a malfunction.
Page 317 BE-56 BODY ELECTRICAL - AIR CONDITIONING Operation The Plasmacluster generator produces positive and negative ions from the water molecules (H O) and oxygen molecules (O ) in the air, and emits them into the air. These ions reduce airborne germs. Positive Ions Airborne Moisture and Oxygen Negative Ions...
Page 318 BE-57 BODY ELECTRICAL - AIR CONDITIONING JSYSTEM CONTROL 1. General The air conditioning system has the following controls. Control Outline Neural Network This control is capable of effecting complex control by artificially simulating the Control information processing method of the nervous system of living organisms in order to [See page BE-58] establish a complex input/output relationship that is similar to a human brain.
Page 319 BE-58 BODY ELECTRICAL - AIR CONDITIONING 2. Neural Network Control D In previous automatic air conditioning systems, the A/C ECU determined the required outlet air temperature and blower air volume in accordance with a calculation formula and based on information received from the sensors.
Page 320 BE-59 BODY ELECTRICAL - AIR CONDITIONING 3. Electric Inverter Compressor Control Compressor Speed Control D The A/C ECU calculates the target compressor speed based on the target evaporator temperature (calculated from the room temperature sensor, outside temp. sensor, and solar sensor) and the actual evaporator temperature detected by the evaporator temperature sensor.
Page 321 BE-60 BODY ELECTRICAL - AIR CONDITIONING 4. Eco Mode Control General D Eco mode control limits the air conditioning system performance during heating and cooling and increases the amount of engine OFF time, thus improving the fuel economy. D Eco mode control is activated by pressing the momentary type ECO switch on the instrument panel. “ECO”...
Page 322 BE-61 BODY ELECTRICAL - AIR CONDITIONING Cooling Mode D When the ECO switch is turned ON during cooling, the A/C ECU limits the power consumption of the electric inverter compressor in accordance with the room temperature. D The A/C ECU does not limit the power consumption very much (C shown in the graph below), and prioritizes decreasing the room temperature when the room temperature is high (T or above).
Page 323 BE-62 BODY ELECTRICAL - AIR CONDITIONING 5. Self-Diagnosis D The A/C ECU has a self-diagnosis function. It stores any operation failures in the air conditioning system memory in the form of DTC (Diagnostic Trouble Code). D There are two methods for reading DTC. One is to use a hand-held tester, and the other is to read DTC indicated on the heater control panel display.
Page 324 BE-63 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM NAVIGATION WITH AV SYSTEM JDESCRIPTION D The navigation with AV system is available as an option. D The design of the screen has been improved in the navigation with AV system in order to improve its visibility.
Page 325 BE-64 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM " System Diagram GPS Antenna Overhead Console D Microphone Module Radio and Player with Display AVC-LAN D Navigation ECU Steering Pad Switch Stereo Amplifier D Map Data Media (DVD) D Gyro Sensor Combination Meter D Vehicle Speed Signal Front LH...
Page 326 BE-65 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM JLAYOUT OF MAIN COMPONENTS Overhead Console D Microphone Module GPS Antenna Combination Meter Radio and Player with Display Stereo Amplifier Steering Pad Switch D VOICE Switch THS ECU Shift Position Sensor 02HBE46TE...
Page 327 BE-66 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM JCONSTRUCTION AND OPERATION 1. General The main functions of the navigation system are listed below. Function Outline D Enlargement/ reduction, rotation and movement of map. D Indication of current position and direction of travel. D Correction of current position.
Page 328 BE-67 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM Function Outline The following screen settings are available: Automatic transition: It enables automatic return to the navigation screen from Screen Setting the audio screen. Switch color: Color of touch-screen button can selected. The following personal data can be deleted or returned to their default settings: D Maintenance conditions D Maintenance information “off”...
Page 329 BE-68 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM 2. Navigation Screen Display D Based on the map data on the DVD, signals from the GPS satellites, signals from the built-in gyro sensor, and signals from the vehicle’s speed sensor, the vehicle’s present position, direction of travel, and driven distance are calculated and displayed on the navigation display.
Page 330 BE-69 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM Item Function Sets multiple destinations. It can also rearrange the sequence of the Multiple Destination Setting destinations. Route Search Searches for multiple routes. Search Condition Searches for the recommended, shortest, and other routes. Designation Regulated Road Route Search...
Page 331 BE-70 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM 3. Information Display Energy Monitor Screen Display The energy monitor screen is displayed as illustrated below. This screen has the display functions listed below. Energy Monitor Display Consumption Switch 02HBE47Y Item Outline D Energy monitor display indicates the energy transmission direction for checking the current drive method (engine, motor or both), the power generation status by the engine and status of regenerative...
Page 332 BE-71 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM Fuel Consumption Screen Display The fuel consumption screen is displayed as illustrated below. This screen has the display functions listed below. Reset All Switches Possible cruising Average fuel distance consumption per minute Recovered Energy Energy Switch Reset Switch...
Page 333 BE-72 BODY ELECTRICAL - NAVIGATION WITH AV SYSTEM 4. Warning Screen Display N, D and B Range Warning When the condition indicated below has been met, the master warning light blinks on the combination meter, a message appears in the multi-information display, and a warning message appears on the display.
Page 334 BE-73 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM BLUETOOTH HANDS-FREE SYSTEM JDESCRIPTION D Bluetooth is a short-distance, high-speed wireless data communication system that uses the 2.4 GHz frequency band prescribed by the Bluetooth SIG (Special Interest Group). D This system enables drivers to place or receive phone calls using a cellular phone without releasing their hands from the steering wheel.
Page 335 BE-74 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM " System Diagram Overhead Console D Microphone Module Bluetooth-Compatible Radio and Player with Cellular Phone Display Combination Meter D Onboard Bluetooth D Vehicle Speed Signal Unit Steering Pad Switch AVC-LAN Stereo Amplifier Speaker 02HBE50TE Models with Navigation with AV System Overhead Console...
Page 336 BE-75 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM JLAYOUT OF MAIN COMPONENTS Radio and Player with Overhead Console D Microphone Module Display D Onboard Bluetooth Models without Navigation with AV System Unit Combination Meter D Vehicle Speed Signal Audio Head Unit D Onboard Bluetooth Unit Steering Pad Switch...
Page 337 BE-76 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM JHANDS-FREE FUNCTIONS (Models with Navigation with AV System) The Bluetooth hands-free system installed on the models with navigation with AV system has the following functions. However, for safety, some functions may not be selectable when the vehicle is being driven. Function Outline By dial...
Page 338 BE-77 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM Function Outline Registering phone number: The user can register phone numbers in the phonebook. Transferring a telephone number: The user can transfer the telephone numbers from the user’s Bluetooth phone to the system. Up to 1,000 data (up to 2 numbers per entry) can be registered in the phonebook.
Page 339 BE-78 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM Function Outline In order to use hands-free function of a Bluetooth phone, it is necessary to register it in the audio head unit. Once a phone is Enter the Bluetooth phone registered, the hands-free function becomes available automatically. The user can register up to 6 Bluetooth phones.
Page 340 BE-79 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM JHANDS-FREE FUNCTIONS (Models without Navigation with AV System) The Bluetooth hands-free system installed on the models without navigation with AV system has the following functions. However, for safety, some functions may not be selectable when the vehicle is being driven.
Page 341 BE-80 BODY ELECTRICAL - BLUETOOTH HANDS-FREE SYSTEM Function Outline The user can register a maximum of 6 speed dials to the function buttons Registering the speed (1 to 6) of the audio head unit by selecting the desired phone numbers dial from the voice recognition registration.
Page 342 BE-81 BODY ELECTRICAL - POWER WINDOW SYSTEM POWER WINDOW SYSTEM JDESCRIPTION The power window system has the following functions: Function Outline This function causes the driver door window to open or close while the power Manual up-and-down window switch is being pulled up or pushed halfway down. Windows other than (All Doors) the driver door window can be opened or closed by fully pulling up or halfway pushing down the switch.
Page 343 BE-82 BODY ELECTRICAL - POWER WINDOW SYSTEM JLAYOUT OF MAIN COMPONENTS Main Body ECU 025BE76TE Power Window Switch (Passenger Side) Power Window Motor Power Window Motor (Passenger Side) (Driver Side) Power Window Motor (Rear RH Side) Power Window Switch (Rear LH Side) Power Window Switch (Rear RH Side) Power Window Motor...
Page 344 BE-83 BODY ELECTRICAL - DOOR LOCK CONTROL SYSTEM DOOR LOCK CONTROL SYSTEM JDESCRIPTION The door lock control system has the following functions: Function Outline Performing the door lock operation with a transmitter (wireless remote) or Manual unlock a key will prohibit the unlock operation by the door lock control switch (door prohibition function mounted interior lock switch).
Page 345 BE-84 BODY ELECTRICAL - DOOR LOCK CONTROL SYSTEM " System Diagram Courtesy Switch Driver Door Lock Assembly (Driver) D Door Lock Motor D Door Position Switch Front Passenger Door Lock Assembly (Front Passenger) D Door Lock Motor D Door Position Switch Door Lock Assembly Rear RH (Rear LH)
Page 346 BE-85 BODY ELECTRICAL - DOOR LOCK CONTROL SYSTEM JLAYOUT OF MAIN COMPONENTS Door Lock Assembly D Door Lock Motor Power Window Master Switch D Door Position Switch D Driver Side Manual Door Lock Switch Main Body ECU Courtesy Switch Courtesy Switch Front Passenger Side Manual Door Lock Switch 02HBE54TE...
Page 347 BE-86 BODY ELECTRICAL - SMART KEY SYSTEM SMART KEY SYSTEM JDESCRIPTION D This system is standard equipment. D The smart key system not only has a wireless door lock remote control function and engine immobilizer function, but by carrying the key the following functions (entry function and push button start function) are also possible without having to use a key or transmitter button.
Page 348 BE-87 BODY ELECTRICAL - SMART KEY SYSTEM JACTUATION AREA The special functions of the key system only work when the key is in the actuation area formed by the eight oscillators. D The front and rear room oscillators form the actuation area of the push button start function. D Front door oscillators and inner and outer trunk oscillators form the actuation area of the entry function.
Page 349 BE-88 BODY ELECTRICAL - SMART KEY SYSTEM JSTART FUNCTION 1. General D While the ignition key must be inserted into the ignition key cylinder and turned from OFF to the START position in order to start the THS II on models without the smart key system, models on which the smart key system is installed start the THS II when the push-type power switch is pressed while the brake pedal is depressed and a key is carried by the driver.
Page 350 BE-89 BODY ELECTRICAL - SMART KEY SYSTEM 2. System Diagram The main body ECU controls the push button start function. The system diagram below shows the components that relate to this function. Power Switch D Transponder Key Amplifier Switch Position Signal ACC Relay Combination Meter...
Page 351 BE-90 BODY ELECTRICAL - SMART KEY SYSTEM 3. Layout of Main Components ID Code Box Main Body ECU Certification ECU Stop Light Switch Power Switch Steering Lock Assembly D Transponder Key Amplifier D Steering Lock/Unlock Detection Switch D Steering Lock ECU D Steering Lock Motor THS ECU Wireless Door Lock Buzzer...
Page 352 BE-91 BODY ELECTRICAL - SMART KEY SYSTEM 4. Function of Main Components Component Function D Transmits the power switch signal to the main body ECU. D Informs the driver of any power source or system abnormality Power Switch through the illumination stage of the indicator light. D Transponder Key Amplifier D Receives the ID code and transmits it to the certification ECU when the key battery is too weak to respond to the tuner based...
Page 353 BE-92 BODY ELECTRICAL - SMART KEY SYSTEM 5. Construction and Operation Power Switch The power switch consists of a momentary type switch, two color (Amber, Green) LEDs, and transponder key amplifier. D The amber and green LEDs are for the indicator light. D The driver can determine the present power source and check whether the engine can start or not in accordance with the illumination state of the indicator light.
Page 354 BE-93 BODY ELECTRICAL - SMART KEY SYSTEM Main Body ECU D Main body ECU consists of the IG relay No.1 and No.2 actuation circuits, CPU, and hold circuit. D The hold circuit is installed to prevent the power supply to the relays from being cut off when an abnormality occurs in IG Relay No.1 and/or No.2 actuation circuits while driving.
Page 355 BE-94 BODY ELECTRICAL - SMART KEY SYSTEM 6. Start Function Operation General The start function has different power source patterns to suit the brake pedal state and shift lever position. Pattern Brake Pedal Shift Lever Power Source Pattern When the power switch is pushed once. When the power switch is pushed once.
Page 356 BE-95 BODY ELECTRICAL - SMART KEY SYSTEM Pattern A: OFF ! READY ON (THS II is start) Step System Operation The driver holds the key and enters the vehicle. When the driver presses the power switch once with the following conditions satisfied, the main body ECU recognizes the power switch signal and transmits the key certification request to the certification ECU.
Page 357 BE-96 BODY ELECTRICAL - SMART KEY SYSTEM Step System Operation The main body ECU turns ON the ACC relay, and then turns ON the IG1and IG2 relays. The certification ECU checks that the power source has switched from OFF to IG-ON, and transmits a steering unlock signal to the main body ECU and ID code box.
Page 358 BE-97 BODY ELECTRICAL - SMART KEY SYSTEM Pattern B: OFF ! ACC ! IG-ON ! OFF 1) OFF ! ACC Step System Operation The driver has the key in their possession and enters the vehicle. When the driver presses the power switch once with the following conditions satisfied, the main body ECU recognizes the power switch signal and transmits the key certification request to the certification ECU.
Page 359 BE-98 BODY ELECTRICAL - SMART KEY SYSTEM 3) IG-ON ! OFF Step System Operation When the power switch is pressed once with the following conditions satisfied, the main body ECU recognizes the power switch signal and turns OFF the ACC, IG relays. D Shift position is P.
Page 360 BE-99 BODY ELECTRICAL - SMART KEY SYSTEM Pattern C: OFF ! ACC ! IG-ON ! ACC Step System Operation The system operations for the power source OFF ! ACC ! IG-ON are the same as those in pattern B. For details, see page BE-97. When the power switch is pressed once with the following conditions satisfied, the main body ECU recognizes the power switch signal and turns OFF the IG relays.
Page 361 After the buzzer sounds, if the power switch is pressed within five seconds while the brake pedal is not depressed, the power source will be switched to ACC or IG-ON in the same way as the normal smart key operation. TOYOTA Mark Power Switch Within 10mm (0.4 in.)
Page 362 BE-101 BODY ELECTRICAL - SMART KEY SYSTEM 7. Diagnosis Main body ECU and certification ECU can detect malfunctions in the smart key system when the power source is in the IG-ON mode. When the ECUs detect a malfunction, the amber indicator light of the power switch flashes to warn the driver. At the same time, the ECUs store 5-digit DTC (Diagnostic Trouble Code) in their memories.
Page 363 BE-102 BODY ELECTRICAL - SMART KEY SYSTEM JENTRY FUNCTION 1. System Diagram The certification ECU controls the entry function. The system diagram below shows the main components that relate to the function. ID Code Box Local Communication Outside Handle Outside Handle Certification Main Body D Antenna...
Page 364 BE-103 BODY ELECTRICAL - SMART KEY SYSTEM 2. Layout of Main Components Wireless Door Lock Buzzer LOCK Button UNLOCK Button TRUNK Button PANIC Button 025BE88Y Multi-information Display Example: ID Code Box Combination Meter D Buzzer Certification ECU Main Body ECU 02HBE65TE...
Page 365 BE-104 BODY ELECTRICAL - SMART KEY SYSTEM Touch Sensor D Antenna Door Oscillator Trunk Oscillator (Inner) Trunk Open Switch Lock Switch Door Outside Handle D Antenna D Touch Sensor D Lock Switch D Door Oscillator Trunk Antenna Trunk Oscillator (Outer) 025BE90TE Tuner Front Room...
Page 366 BE-105 BODY ELECTRICAL - SMART KEY SYSTEM 3. Function of Main Components Component Function The key consists of a mechanical key, the transmitter for the wireless door lock remote control, the transceiver for the smart key system and a transponder chip for the HV immobilizer control. Controls the smart key system in accordance with the signals from each oscillator, various switches, ECUs and the key.
Page 367 BE-106 BODY ELECTRICAL - SMART KEY SYSTEM 4. Construction and Operation The key consists of a mechanical key, a transmitter for the wireless door lock remote control and a transceiver for the smart key system, and a transponder chip for the engine immobilizer control. D The transceiver function of the key receives the signals from the oscillators and returns the ID code to the tuner.
Page 368 BE-107 BODY ELECTRICAL - SMART KEY SYSTEM 5. Entry Function Operation General The entry function has the following functions. Function Outline The key consists of a mechanical key, a transmitter for the wireless door lock remote Mechanical Key control and a transceiver for the smart key system, and a transponder chip for the HV [See page BE-106] immobilizer control.
Page 369 BE-108 BODY ELECTRICAL - SMART KEY SYSTEM Wireless Door Lock Remote Control Function The wireless door lock remote control function has the following functions: Function Outline All Doors Lock Pressing the LOCK button of the transmitter locks all doors. All Doors Unlock Pressing the UNLOCK button of the transmitter (key) unlocks all doors.
Page 370 BE-109 BODY ELECTRICAL - SMART KEY SYSTEM Entry Unlock a) When a key enters any actuation area of the door oscillators, the certification ECU judges and certifies the key ID code received from the tuner. b) After the key certification OK is confirmed, the certification ECU transmits an unlock stand-by signal to the touch sensor of the relevant door.
Page 371 BE-110 BODY ELECTRICAL - SMART KEY SYSTEM Entry Unlock Mode Switching a) When the power source is OFF, press the lock button and one of the other three buttons on the key at the same time for approximately 5 seconds while the key is in the actuation area. b) The certification ECU receives this signal from the tuner and switches the entry unlock mode.
Page 372 BE-111 BODY ELECTRICAL - SMART KEY SYSTEM Entry Lock Function a) This signal is transmitted to the certification ECU when the driver (who has the key in their possession), exits the vehicle and presses the lock switch on the outside door handle. b) The certification ECU transmits a request signal for all door and room oscillators to form actuation areas.
Page 373 BE-112 BODY ELECTRICAL - SMART KEY SYSTEM Trunk Open Function a) This signal is transmitted to the certification ECU when the driver (who has the key in their possession) pushes the trunk open switch on the outside of the trunk lid. b) The certification ECU transmits a request signal for all the room, trunk inner and outer oscillators to form actuation areas.
Page 374 BE-113 BODY ELECTRICAL - SMART KEY SYSTEM Prevention of Key Confinement 1) General This function has two system operations: inside room (cabin) and inside luggage compartment. 2) Inside Room a) When the door is locked with the outside door handle while the key is still inside the vehicle, the certification ECU receives this signal and transmits a request signal for the front and rear room oscillators to form a actuation area.
Page 375 BE-114 BODY ELECTRICAL - SMART KEY SYSTEM 3) Inside Luggage Room a) When the trunk lid is closed while the key is still inside the luggage room and all doors are locked, the certification ECU recognizes that a trunk lid close condition has occurred based on signals from the main body ECU.
Page 376 BE-115 BODY ELECTRICAL - SMART KEY SYSTEM Warning 1) General When any of the situations below occur, the smart key system causes the certification ECU to sound a buzzer in the combination meter and the wireless door lock buzzer, and illuminate the multi-information display in order to the alert the driver.
Page 377 BE-116 BODY ELECTRICAL - SMART KEY SYSTEM 2) Situation: A There are two patterns for situation A. D Pattern 1: When the shift lever is in any position other than P, the driver opens the door and attempts to get out of the vehicle. D Pattern 2: Under the conditions of pattern 1, the driver closes the door and attempts to leave the vehicle holding the key.
Page 378 BE-117 BODY ELECTRICAL - SMART KEY SYSTEM D Key is in the vehicle. D The wireless door lock buzzer stops. D Multi-information Display: 025BE99P D Vehicle speed is above 0 mph (0 km/h). Warning Stop Condition Warning Stop Condition D The wireless door lock buzzer stops. D Multi-information Display: 025BE100P D Power source is OFF.
Page 379 BE-118 BODY ELECTRICAL - SMART KEY SYSTEM 4) Situation: C There are two patterns for situation C. D Pattern 1: When the shift lever is in the P position, the driver closes the driver’s door and attempts to leave the vehicle while holding the key. D Pattern 2: Under the conditions of pattern 1, the driver presses the lock switch on the door outside handle.
Page 380 BE-119 BODY ELECTRICAL - SMART KEY SYSTEM Pattern 2. Possible Effects without Warning Vehicle theft, Discharged battery The warning is activated when all of the following conditions are met: D Shift lever is P. D Power source is in a mode other than OFF. Warning Condition D All doors are closed.
Page 381 BE-120 BODY ELECTRICAL - SMART KEY SYSTEM 6) Situation: E When the engine is left running, a passenger leaves the vehicle holding the key. In this situation, the following control is performed: Possible Effects without Warning Engine cannot be restarted The warning is activated when all of the following conditions are met: D Power source is in a mode other than OFF.
Page 382 BE-121 BODY ELECTRICAL - SMART KEY SYSTEM 8) Situation: G The lock switch on the door outside handle is pressed to perform entry lock with the key left in the cabin. In this situation, the following control is performed: Possible Effects without Warning Vehicle theft The warning is activated when all of the following conditions are met:...
Page 383 BE-122 BODY ELECTRICAL - SMART KEY SYSTEM 10) Situation: I The vehicle is driven using a key that has a low battery. In this situation, the following control is performed: Possible Effects without Warning Smart key system does not function The warning is activated when all of the following conditions are met: D Power source switches to OFF after being left in IG-ON...
Page 384 BE-123 BODY ELECTRICAL - SMART KEY SYSTEM 12) Situation: K A malfunction of the steering lock ECU is detected. In this situation, the following control is performed: Possible Effects without Warning Malfunction detection Warning Condition A malfunction of the steering lock ECU is detected. Buzzer —...
Page 385 BE-124 BODY ELECTRICAL - SMART KEY SYSTEM 14) Situation: M A warning message appears on the meter when the driver does not follow the proper procedure to start the vehicle. In this situation, the following control is performed: Possible Effects without Warning Usability function The warning is activated when all of the following conditions are met:...
Page 386 BE-125 BODY ELECTRICAL - SMART KEY SYSTEM Battery Saving 1) Vehicle Battery Saving Function In the smart key system, signals are emitted outside the vehicle at a prescribed interval (250 msec.) when the doors are locked. Therefore, the vehicle battery could be drained if the vehicle remains parked for a long time.
Page 387 BE-126 BODY ELECTRICAL - SMART KEY SYSTEM Key Cancel Key cancel is operated when certain operations are performed with the vehicle in the following condition: D Power source is OFF. D Driver door is closed. D Driver door is unlocked. The operation procedure is as follows: 1) Unlock once with the UNLOCK button of the key.
Page 388: Srs Airbag System
BE-127 BODY ELECTRICAL - SRS AIRBAG SYSTEM SRS AIRBAG SYSTEM JDESCRIPTION 1. General D The driver and front passenger dual-stage SRS (Supplemental Restraint System) airbags supplement the seat belts to help to reduce the shocks to the head and chest of the driver and front passenger in the event of a frontal collision.
Page 389 BE-128 BODY ELECTRICAL - SRS AIRBAG SYSTEM JLAYOUT OF MAIN COMPONENTS Front Airbag Sensor Front Passenger Indicator D AIRBAG ON/OFF Indicator Light Front Passenger Airbag Airbag Sensor Assembly Front Passenger Driver Airbag Side Airbag DLC3 Knee Airbag Seat Belt Buckle Switch Driver Side Airbag SRS Warning Light...
Page 390 BE-129 BODY ELECTRICAL - SRS AIRBAG SYSTEM JWIRING DIAGRAM Spiral Cable Front Passenger Driver Airbag Airbag Seat Belt Driver Knee Pretensioner Airbag (Front Passenger) Seat Belt SFP+ Pretensioner Side Airbag SFP- (Driver) (Front Passenger) SFD+ Side Airbag ICP+ SFD- (Driver) Curtain Shield ICP- Airbag (RH)
Page 391 BE-130 BODY ELECTRICAL - SRS AIRBAG SYSTEM JAIRBAG FOR FRONTAL COLLISION 1. General D In conjunction with their impact absorbing structure for frontal collisions, the driver and front passenger dual-stage SRS airbags and the driver knee airbag deploy simultaneously, and are supplements to the seat belts.
Page 392 BE-131 BODY ELECTRICAL - SRS AIRBAG SYSTEM 2. Dual-stage SRS Airbag System General In this system, when the front airbag sensors and airbag sensor assembly detect a front collision, the airbag sensor assembly judges the extent of impact, seat position and whether or not the seat belts are fastened, thus optimizing the airbag inflating output by delaying the inflation timing of the 2nd initiator and the 1st initiator.
Page 393 BE-132 BODY ELECTRICAL - SRS AIRBAG SYSTEM Service Tip Follow the procedure indicated below to install the seat position sensor. 1) Insert a 1.0 mm (0.04 in.) feeler gauge between the seat position sensor and the lower rail portion. 2) Tighten the mounting bolt to the specified torque with the seat position sensor pushed down as shown.
Page 394 BE-133 BODY ELECTRICAL - SRS AIRBAG SYSTEM 3. SRS Driver and Front Passenger Airbags SRS driver and front passenger airbags contain two sets of initiators and propellants. The airbag sensor assembly helps optimize the airbag inflation speed by controlling the inflation timing of these initiators. 4.
Page 395 BE-134 BODY ELECTRICAL - SRS AIRBAG SYSTEM JAIRBAG FOR SIDE/REAR OF SIDE COLLISION 1. General D With the airbag for side collisions, if the side & curtain shield airbag sensor detects an impact, the airbag sensor assembly causes the front side and curtain shield airbags to be deployed simultaneously. D With the airbag for rear of side collisions, if the curtain shield airbag sensor detects an impact, the airbag sensor assembly causes the curtain shield airbag to be deployed.
Page 396 BE-135 BODY ELECTRICAL - SRS AIRBAG SYSTEM 2. SRS Side Airbag SRS side airbags are installed in the backs of the driver seat and the front passenger seat. The SRS airbag is a one-piece design, consisting of an inflator, a bag, and a cover. 3.
Page 397 BE-136 BODY ELECTRICAL - SRS AIRBAG SYSTEM JFRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM 1. General The front passenger occupant classification system judges whether the front passenger seat is occupied by an adult or child (with child seat) or is unoccupied, in accordance with the load that is applied to the front passenger seat and whether the seat belt is buckled.
Page 398 BE-137 BODY ELECTRICAL - SRS AIRBAG SYSTEM 2. Wiring Diagram SVC1 SVC2 Occupant Classification Occupant Classification SIG1 SIG2 Sensor (Front RH) Sensor (Front LH) SGD1 SGD2 SVC3 SVC4 Occupant Classification Occupant Classification SIG3 SIG4 Sensor (Rear LH) Sensor (Rear RH) SGD3 SGD4 Occupant...
Page 399 BE-138 BODY ELECTRICAL - SRS AIRBAG SYSTEM 3. Occupant Classification Sensor The occupant classification sensors are installed on four brackets connecting the seat rail and the seat frame. The resistance values of these sensors, which vary in accordance with the distortion that acts on the brackets, are output to the occupant classification ECU.
Page 400 BE-139 BODY ELECTRICAL - SRS AIRBAG SYSTEM 4. System Operation General This system makes the following judgments: unoccupied judgment, child seat judgment, child judgment, and adult judgment. In addition, it performs an initial check to check the circuit of the AIRBAG ON/OFF indicator lights when the power switch is IG-ON.
Page 401 BE-140 BODY ELECTRICAL - SRS AIRBAG SYSTEM Child Seat or Child Judgment D If the judgment value is lower than criteria value B and the seat belt buckle switch is ON, the occupant classification ECU judges that a child seat is installed. D If the judgment value is higher than criteria value A, but lower than criteria value B, and the seat belt buckle switch is OFF, the occupant classification ECU judges that the seat is being occupied by a child.
Page 402 BE-141 BODY ELECTRICAL - SRS AIRBAG SYSTEM Adult Judgment D When the judgment value is higher than criteria value B, the occupant classification ECU judges that the seat is being occupied by an adult. D If the power switch is turned IG-ON in this state, the system performs an initial check and illuminates the AIRBAG ON indicator light, indicating that the front passenger airbag and the front passenger side airbag are active.
Page 403 BE-142 BODY ELECTRICAL - SRS AIRBAG SYSTEM Initial Check After the power switch is tuned IG-ON, the occupant classification ECU lights up the AIRBAG ON/OFF indicator lights via airbag sensor assembly based on the timing chart below in order to check the indicator light circuits.
Page 404 BE-143 BODY ELECTRICAL - SRS AIRBAG SYSTEM 5. Precaution for Front Passenger Occupant Classification System Operation To avoid potential death or serious injury when the front passenger occupant classification system does not detect the conditions correctly, observe the following. D Wear the seat belt properly. D Make sure the front passenger’s seat belt tab has not been left inserted into the buckle before someone sits in the front passenger seat.
Page 405 BE-144 BODY ELECTRICAL - SRS AIRBAG SYSTEM JIMPROPER CONNECTION PREVENTION LOCK MECHANISM D This improper connection prevention lock mechanism consists of the airbag sensor assembly and the holder. D The airbag sensor assembly has a connector lock pin. D The holder has a lever with a lock groove. The holder and the connectors are locked via a retainer and a lance.
Page 406 Unlike general data recorders, the EDR does not record sound data such as conversation between passengers. Toyota will not disclose the data recorded in an EDR to a third party except when: D An agreement from the vehicle’s owner (or the leasing company for a leased vehicle) is obtained...
Page 407 BE-146 ODY ELECTRICAL - SEAT BELT REMINDER SYSTEM SEAT BELT REMINDER SYSTEM JDESCRIPTION D If a seat belt is not fastened, this system flashes the seat belt reminder light or sounds the buzzer in the combination meter as a reminder. D When the power switch is turned IG-ON, this system detects the condition of the seat belts based on the signals from the seat belt buckle switches (for the driver and front passenger) and the occupant classification sensors.
Page 408 BE-147 ODY ELECTRICAL - SEAT BELT REMINDER SYSTEM JREMINDER METHOD The timing chart of the buzzer and details of the reminder method are shown below. " Timing Chart IG-ON Power Switch Vehicle 20km / h (12mph) or more Speed 0 mph Seat Belt Not Fasten Buckle...
Page 409: Cruise Control System
BE-148 BODY ELECTRICAL - CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM JDESCRIPTION D The cruise control system is standard equipment on all models. D This system, which is controlled by the THS ECU that is integrated with the cruise control ECU, operates the vehicle through an optimal combination of the motive forces of the MG2 and the engine in accordance with the setting on the cruise control switch.
Page 410 BE-149 BODY ELECTRICAL - CRUISE CONTROL SYSTEM 2. Layout of Main Components Cruise MAIN Indicator Light Cruise Control Switch DLC3 THS ECU Throttle Body D Throttle Control Motor Accelerator Pedal Stop Light Switch Position Sensor Inverter Shift Position Sensor 02HBE73TE...
Page 411 BE-150 BODY ELECTRICAL - CRUISE CONTROL SYSTEM 3. System Control General The cruise control has the following control. Control Outline The THS ECU compares the actual vehicle speed with the set speed, and regulates Constant Speed the drive force of the MG2 and the engine so that the actual vehicle speed and the Control set speed will become equal.
Page 412 BE-151 BODY ELECTRICAL - CRUISE CONTROL SYSTEM Control Outline If any of the following signals is sent to the THS ECU, the cruise control is cancelled accordingly. D Stop light switch ON signal/Depress the brake pedal. D Stop light switch ON signal/Depress the brake pedal. Manual Cancel Manual Cancel D CANCEL switch ON signal (cruise control switch moved to CANCEL side)
Page 413 BE-152 BODY ELECTRICAL - CRUISE CONTROL SYSTEM Diagnosis If a malfunction occurs in the cruise control system, during cruise control operation, the THS ECU actuates the automatic cancel control and blinks the cruise MAIN indicator light to inform the driver of a malfunction.
Page 414: Rear View Mirror
BE-153 BODY ELECTRICAL - REAR VIEW MIRROR REAR VIEW MIRROR JDESCRIPTION The rear view mirrors have the following functions: Mirror Function Equipment Inside Rear Automatic glare-resistant EC (Electrochromic) mirror & compass Standard View Mirror display Electric remote control mirror Standard Outside Rear Outside Rear View Mirror...
Page 415 BE-154 BE-154 BODY ELECTRICAL - REAR VIEW MIRROR JCOMPASS DISPLAY A sensor that detects the earth’s magnetic field is built inside the inside rear view mirror. This sensor is influenced less by the magnetization of the vehicle. D The compass indicates north as 0_ and the forward direction of the vehicle using 8 azimuths. (N, NE, E, SE, S, SW, W, and NW) D Press the Mirror switch for 3 to 6 seconds to indicate the compass.
Page 416 BE-155 BODY ELECTRICAL - REAR VIEW MIRROR JAUTOMATIC GLARE-RESISTANT EC MIRROR 1. General During nighttime driving, if a large difference in intensity exists between the surrounding light and the light reflected off the inside rear view mirror from the headlights behind, an automatic glare-resistant EC (Electrochromic) mirror automatically reduces the reflection rate of the mirror and thus dampens the glare from the mirror.
Page 417 BE-156 BODY ELECTRICAL - REAR VIEW MIRROR 3. EC Mirror Cell The gel type EC elements are placed between a layer of transparent conductive coating, and a layer of conductive reflector surfaces, which are placed between 2 sheets of glasses. The EC elements have color coating characteristics.
Page 418 BE-157 BODY ELECTRICAL - POWER SEAT SYSTEM POWER SEAT SYSTEM JDESCRIPTION D A power seat system is used for the driver and front passenger seats on all models. D The power seat system for the front seats has the functions: f: Standard Equipment Function...
Page 419 BE-158 BODY ELECTRICAL - SEAT HEATER SYSTEM SEAT HEATER SYSTEM JDESCRIPTION D This system is optional equipment on the driver and front passenger seats of leather seat models. D A seat heater switch with a built-in indicator light for checking the heater operation is provided. D The output temperature of the seat heater is controlled by thermostat that are enclosed in the cushion.
Page 420: Rear Window Defogger System
BE-159 BODY ELECTRICAL - REAR WINDOW DEFOGGER SYSTEM REAR WINDOW DEFOGGER SYSTEM JDESCRIPTION D The rear window defogger system uses the heater wire on the rear window glass to defog the rear window glass. D This system is standard equipment on all models. D The rear window defogger system operates at the same time as the heater function* of the outside rear view mirror.
Page 421 BE-160 BODY ELECTRICAL - REAR WINDOW DEFOGGER SYSTEM JLAYOUT OF MAIN COMPONENTS Heater Control Panel Rear Window Defogger Switch Outside Rear View Mirror D Mirror Heater* A/C ECU RR DEF Relay Engine Room R/B No.1 Rear Window Defogger 02HBE74TE *: Available as an option...
Page 422 BE-161 BODY ELECTRICAL - SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM JDESCRIPTION D Sliding roof system is optional equipment. D This system uses a single glass panel to perform tilt-up-down and open-and-close operations. D The sliding roof ECU uses 2 type Hall ICs to detect the position of the sliding roof. Sliding roof ECU and the 2 Hall ICs are integrated into the sliding roof motor assembly.
Page 423 BE-162 BODY ELECTRICAL - SLIDING ROOF SYSTEM JFUNCTION 1. General This sliding roof system has the following functions: Function Outline This function causes the sliding roof to open (or close) while the SLIDE OPEN Manual switch (or SLIDE CLOSE switch) is pressed. The sliding roof stops as soon as the open-and-close switch is released.
Page 424 BE-163 BODY ELECTRICAL - SLIDING ROOF SYSTEM 2. Jam Protection Function D The Hall IC converts the changes in the magnetic flux that occur due to the rotation of the worm gear into pulse signals and outputs them to the ECU. Sliding Roof Motor Hall IC Sliding Roof ECU...
Page 425 BE-164 BODY ELECTRICAL - SLIDING ROOF SYSTEM 3. Sliding Roof Open Warning When the power switch is changed from IG-ON to OFF and the driver door is opened when the sliding roof is open, the siding roof ECU sounds the buzzer in the combination meter. Then, a warning message appears on the multi-information display.
Page 426: Garage Door Opener
BE-165 BODY ELECTRICAL - GARAGE DOOR OPENER GARAGE DOOR OPENER JDESCRIPTION The garage door opener system is standard equipment. This system enables the garage door to be opened or closed from inside the vehicle by operating the switch. This system provides the features listed below. D Up to three types of transmitter codes can be registered in the garage door opener.
Page 427 BE-166 BODY ELECTRICAL - GARAGE DOOR OPENER JTRANSMITTER CODE REGISTRATION PROCEDURE The garage door opener contains an EEPROM in which the maximum of 3 types of transmitter recognition codes can be registered. A transmitter code is registered into the EEPROM of the garage door opener according to the following steps.
Page 428 BE-167 BODY ELECTRICAL - TRUNK OPENER TRUNK OPENER JDESCRIPTION The trunk opener can be operated through the key or lever. For models equipped with the smart key system, see page BE-86. " System Diagram Luggage Compartment Tuner Door Lock Assembly D Trunk Opener Motor Main Body Certification...
Page 429 BE-168 BODY ELECTRICAL - STEERING PAD SWITCH STEERING PAD SWITCH JDESCRIPTION D Steering pad switches are standard equipment on all models. D For details about the steering pad switches, refer to the table below. System Switch D VOLUME +/- D SEEK +/- Audio D MODE Multi-information Display...
Page 430 AP-2 APPENDIX MAJOR TECHNICAL SPECIFICATIONS Area U.S.A. and Canada Item Body Type Sedan Vehicle Grade — Model Code AHV40L-AEXGBA Length mm (in.) 4805 (177.5) 1820 (71.7) Overall Width mm (in.) Height mm (in.) 1460 (57.5) Wheel Base mm (in.) 2775 (109.3) Front mm (in.) 1575 (62.0)

Toyota Camry Hybrid AHV40 Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Toyota Camry Hybrid AHV40

Summary of Contents for Toyota Camry Hybrid AHV40

Table of Contents