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2006 - 2011 Toyota Camry Hybrid Installation Instructions

(Click on below image
for larger photo)

Time Required: Approx 2-2.5 hours

Tools Required:
Trim panel removal tool
8mm, 10mm, 12mm sockets
Wire cutters, wire strippers
Zip tie cutters or scissors
#0 flat heat screwdriver
#2 phillips screwdriver, #0 phillips screwdriver

Recommended: Electrical safety gloves, Volt meter
Magnetic pickup tool

1) Open the trunk and remove the trunk mat (if equipped) and trunk carpet.

Remove rear cargo area center carpet base

2) Remove the trunk floor retainer screw and the trunk floor panel.
3) Remove the 12V aux battery cover.

4) Disconnect the 12V aux battery.

DO NOT SKIP THIS STEP!

5) Lift the flap and remove the hybrid traction battery main disconnect by pulling out/down on the large orange disconnect lock ring, rotating it down 90 degrees, and removing the disconnect.

6) Remove the rear battery carpet cover. It is only held in by Velcro, it is easy to remove.

7) Remove rear trunk panel by first removing two cargo hooks from top rear sides of trunk with 8mm socket or a phillips screwdriver (not shown).

Remove the rear panel by pulling the bottom of the panel forward toward the front of the car to release the lower clips, then pull straight up to release the upper clips.

8) Using trim panel removal tool, remove the two trunk side panel clips and remove the trunk side panel.

9) Remove the four 12mm nuts holding the rear seat backs.

Remove the rear seat backs.

10) Remove the three push clips and remove the forward battery trim carpet.

11) Using the pin on top of battery disconnect switch handle loop, rotate safety clip lock at least 90 degrees counter clockwise to release safety lock pin.

Remove safety lock pin.

12) Remove push pin (1), DC/DC converter ventilation duct (2), fan housing clip (3) and disconnect fan harness plug (4).
13) Remove two clips and remove battery intake vent duct.

14) Remove three 10mm bolts holding hybrid battery cooling fan.

Remove the hybrid battery cooling fan by lifting overhead duct and sliding fan forward toward front of vehicle as shown.

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OPTIONAL BUT RECOMMENDED:

15) We highly recommend taking a few extra minutes to clean the hybrid battery cooling fan. The fan has no filter on the intake duct and often becomes clogged with debris. This contributes heavily to the hybrid battery overheating and premature failure.

Remove the hybrid battery cooling fan intake duct by removing the black retention clip. Reach into the fan and clean it in place or carefully remove the three 10mm bolts and remove the fan from the car to clean it.

16) Remove three 10mm bolts holding junction box left side cover. Two are visible in this photo and there is a small wrench (in the red box) on the third bolt.

Shift cover out of the way. (You can leave wire harness connected and leave it in the car, it will not be in the way.)

17) Remove the 10mm bolt and 10mm nut and remove the wire routing cover.
18) Remove two 10mm nuts holding ground cable and remove ground cable.

19) Remove the 10mm bolt and two 10mm nuts.

Remove the junction box right side cover.

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WARNING

20) You are now dealing with exposed high voltage module terminals. Do not touch the terminals unless specifically advised by these instructions. Never touch more than one terminal at a time. Be very careful working around the semi-live battery! It can kill you if you do not respect it!

21) Using a multi-meter, test the battery for voltage. There should be less than 5V present.

We recommend using electrically insulated gloves for all steps requiring contact with HV battery cables.

After confirming no voltage is present, remove the two 10mm nuts and remove HV cables and retainer spring.

22) Unplug the chassis wire harness.

Remove the 10mm nut holding the battery cable to the battery cover.

23) Remove eleven 10mm nuts and remove the junction box cover.
24) Using a trim panel removal tool, remove the six wire stays that are clipped onto the battery cover.

25) Remove one 10mm nut (out of view - see wrench in photo) and one 10mm bolt from front side of battery disconnect relay housing.

Remove 10mm nut and 10mm bolt from front side of DC/DC converter.

26) Shift wires forward as needed and remove 10mm bolt from rear of battery disconnect relay housing.

A magnetic pickup tool can help make removal and reinstallation of these bolts much easier.

27) Shift wires forward as needed and remove the two 10mm bolts from rear of DC/DC converter.

28) Shift battery disconnect relay housing and DC/DC converter forward to gain access to the battery disconnect relay housing ground cable.

Remove 10mm nut holding ground cable.

Shift battery disconnect relay housing and DC/DC converter forward as much as possible to gain access to battery cover.

29) Remove 10mm bolt from battery voltage sensor.

Shift battery voltage sensor forward as much as possible to gain access to battery cover.

30) Remove two remaining 10mm front battery cover bolts.

Remove two 10mm battery end cover top bolts as shown.

31) Slice foam along seam at corner of battery.

32) Remove three 10mm battery side panel bolts.

Remove four 12mm battery cover bolts.

Remove battery cover by lifting striaght up and removing from vehicle through the trunk.

33) Begin harness installation by cutting the fan wires approx 2 inches (50mm) from back of plug.

Remove and discard black wire tubing.

Click on diagram
at right for
larger image

34) Strip 1/8 inch (3.2mm) of insulation off of each wire.

Carefully install each wire into the hybrid battery cooling fan control sub-assembly using the wire diagram shown above.

Be sure connections are tight! Try pulling the wires out, they should be firmly in place!

This is what it should look like when both connections are made.

35) Carefully install hybrid battery cooling fan control sub-assembly enclosure lid using four provided screws.

NOTE LID ORIENTATION, it is not symmetrical. There are alignment tabs at one end to ensure proper installation.

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36) Note: Should you ever need/want to reverse the installation of the car harness, we are happy to provide a blank four pin connection terminal for a nominal fee to allow removal of wire harness.
37) Attach fan control enclosure to fan assembly using supplied large zip tie as shown.
38) Using very small (#0) flat head screwdriver, carefully remove black battery module cover all the way across front of battery. Note there is a small inner clip on each piece that will need to be carefully detached as well. It is not difficult, just take your time and do not rush this step.
39) This is what it will look like when the covers are removed.

40) Install the black HV ground wire to the right most (passenger side) battery module 8mm bolt as shown.

When tightening the battery module terminal 8mm nut, DO NOT OVERTIGHTEN! These post can break if too much force is used. They should only be torqued to approx 10 ft lb.

Route the black HV negative wire across the battery pack by passing it through the orange battery wire harness clips as shown.

41) Install the red HV positive wire to the left most (driver side) battery module 8mm bolt as shown. Note how the red & black wires are routed under the battery insulating foam. This is intentional.

When tightening the battery module terminal 8mm nut, DO NOT OVERTIGHTEN! These post can break if too much force is used. They should only be torqued to approx 10 ft lb.

42) Reinstall black battery module covers all the way accross front of battery. Note there is a small inner clip on each piece that will need to be carefully reattached as well

43) Reinstall hybrid battery cover being careful that end cap studs are aligned.

Do not install hardware until instructed to. We will be testing the harness installation first.

44) Slide battery cooling fan into position as shown. Do not bolt into place yet.
45) Guide car harness into trunk area and loosely attach harness anti-tension ring to 10mm bolt as shown.

46) IMPORTANT - Test the charger before finishing re-assembly of the vehicle. We recommend that you connect the charger to the car harness before plugging it into the wall and unplug it from the wall before disconnecting it from the car harness.

To perform the initial function test: First, make sure all fingers and tools are clear of all wiring and hybrid battery components. Plug the charger into the car harness. With the hybrid battery main disconnect still removed, plug the charger into the wall. After a few seconds, it should read approx 280 volts on the meter and both the charger and hybrid battery cooling fans should be running.

Note in the image at left the hybrid battery main disconnect is not present and the charger is displaying no amperage.

47) Next, carefully connect hybrid battery main disconnect.

Once the disconnect is reinstalled, be sure to PUSH THE LARGE ORANGE DISCONNECT RING DOWN TO LOCK IT INTO PLACE!! IT WILL NOT WORK UNLESS LOCKED DOWN. YOU HAVE TO PUSH IT DOWN TO LOCK IT IN PLACE.

(2004-2009 diagram shown, but the locking action is the same.)

48) You should see the voltage drop as the charger voltage equalizes with the voltage level of the battery pack. This should happen quickly. The voltage level should be stable and not fluctuating. All fans should still be running.

Note in the image at left the hybrid battery main disconnect is present and the charger is displaying battery voltage and amperage.

If anything is wrong, stop and contact us. If the fan is ‘pulsing’ (powering on and off) every few seconds, stop and contact us.

This completes the test. Unplug the Charger from the AC power source.

49) Remove the main disconnect from the battery in order to complete the installation process.

Disconnect the charger from the car harness.

50) Reinstall the four 12mm battery cover bolts.

Reinstall the four battery side cover bolts.

Reinstall the three 10mm battery cooling fan bolts.

51) Using the two provided small zip ties, secure wire harness fuse holder as shown.
52) Reinstall two front left (driver side) battery cover 10mm bolts.
53) Reposition the battery voltage sensor assembly and install one 10mm bolt as shown.

54) Reposition disconnect relay housing and DC/DC converter into their respective position.

Position disconnect relay housing ground cable as shown.

Install final 10mm forward battery cover nut.

Install disconnect relay housing 10mm mount nut.

55) Install 10mm battery wire cable nut.

Install two remaining disconnect relay housing 10mm mount bolts.

Install front DC/DC converter 10mm mount nut.

Install three remaining DC/DC converter 10mm mount bolts.

56) Reinstall the HV cables, two 10mm nuts, and retainer spring.

Reinstall the six wire stays that are clipped onto the battery cover.

Reconnect the chassis wire harness.

57) Reinstall the junction box cover and secure the eleven 10mm nuts.

Reinstall the left side junction box cover and secure with three 10mm bolts.

58) Reinstall left side control box cover.

Install ground wire harness as shown.

Secure both with five 10mm nuts and one 10mm bolt as shown.

59) Reinstall 10mm bolt and 10mm nut and reinstall the wire routing cover.

Reinstall orange safety lock pin

60) Reconnect fan wire harness.

Reinstall DC/DC converter cooling pipe & cooling pipe push pin.

Reinstall fan housing clip.

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61) Install forward battery carpet cover and three push clips.

Install the left & right rear seat backs.

62) Install trunk side panel and route wire harness as shown.
63) Install rear battery cover carpet trim panel and route wire harness as shown.

64) Install rear trunk trim panel.

Install rear cargo hooks

Reconnect 12V aux battery & battery cover.

Install hybrid battery main disconnect switch, being sure to lock it all the way down into place.

Install trunk floor retainer screw and the trunk floor panel

Install trunk carpet and trunk mat (if equipped).

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Click here for the Prolong Battery Charger User Guide.


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