Toyota Highlander Dismantling Manual
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Toyota Highlander Dismantling Manual

Mhu23/28 series gasoline-electric hybrid synergy drive
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See also: Service Manual , Owner's Manual
Gasoline-Electric
Hybrid Synergy Drive
MHU23/28 Series

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Summary of Contents for Toyota Highlander

  • Page 1 Gasoline-Electric Hybrid Synergy Drive MHU23/28 Series...
  • Page 2 Highlander gasoline-electric hybrid vehicle. Highlander dismantling procedures are similar to other Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota Highlander as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    Table of Contents ABOUT THE HIGHLANDER........................1 HIGHLANDER IDENTIFICATION ....................... 2 Exterior...................................3 Interior....................................4 Engine Compartment..............................5 HYBRID COMPONENT LOCATIONS & DESCRIPTIONS ............... 6 Specifications .................................7 HYBRID SYNERGY DRIVE OPERATION ................... 8 HV Battery Pack................................9 Components Powered by the HV Battery Pack ......................9 HV Battery Pack Recycling............................10...

  • Page 5: About The Highlander

    The result of combining these two power sources is improved fuel economy and reduced emissions. The gasoline engine also powers an electric generator to recharge the battery pack; unlike a pure all electric vehicle, the Highlander never needs to be recharged from an external electric power source.

  • Page 6: Highlander Identification

    Highlander Identification In appearance, the Highlander is nearly identical to the conventional, non-hybrid Toyota Highlander. The Highlander is a 5-door SUV. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl, driver doorpost and passenger side frame.

  • Page 7: Exterior

    Exterior n Hybrid Synergy Drive & Highlander logos on back door. o Gasoline fuel filler door located on left side quarter panel. p Toyota logo on the hood. HIGHLANDER n Hybrid Synergy Drive Exterior Rear & Left Side View Exterior Left Side View...

  • Page 8: Interior

    G Instrument cluster (speedometer, fuel gauge, warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid Highlander. H In place of a tachometer, a power meter showing KW output is used.

  • Page 9: Engine Compartment

    Engine Compartment s 3.3-liter aluminum alloy gasoline engine. t High voltage inverter/converter assembly with logo on the cover. u Orange colored high voltage power cables. HYBRID SYNERGY DRIVE Logo on Inverter Engine Compartment...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description 12-Volt Engine Compartment Lead-acid battery powers all low voltage electrical equipment except Auxiliary electric motor, generator, inverter/converter, A/C compressor, and electric Battery n power steering. Hybrid Cabin Area, Mounted to 288-Volt Nickel Metal Hydride (NiMH) battery pack consisting of 30 low Vehicle (HV) Cross Member...

  • Page 11: Specifications

    Specifications Gasoline Engine: 208 hp, 3.3 liter Aluminum Alloy Engine Electric Motor: Front: 165hp, Permanent Magnet Motor Rear: 67hp, Permanent Magnet Motor (4WD Model Only) Transmission: Automatic Only HV Battery: 288-Volt Sealed NiMH Curb Weight: North America: 4,068lbs (2WD) North America: 4,244Ibs (4WD) Fuel Tank: 14.3 gals Body Material:...

  • Page 12: Hybrid Synergy Drive Operation

    Vehicle Operation With the Highlander, the gasoline engine may stop and start at any time while the READY indicator is on. Never assume that the vehicle is shut off just because the engine is off. Always look for the READY indicator status.

  • Page 13: Hv Battery Pack

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The Highlander contains a next generation high voltage, Hybrid Vehicle (HV) battery pack and a low voltage auxiliary battery. The HV battery pack contains non-spillable, sealed Nickel Metal Hydride (NiMH) battery modules and the auxiliary battery is a typical automotive lead-acid type.

  • Page 14: Hv Battery Pack Recycling

    HV Battery Pack Recycling The HV battery pack is recyclable. Contact your Toyota Distributor as mentioned on HV battery Caution Label (see the page 26) or the nearest Toyota dealer. Auxiliary Battery The Highlander also contains a lead-acid 12-Volt battery. This 12-Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle.

  • Page 15: High Voltage Safety

    High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative high voltage power cables are routed from the battery pack, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 288 to 650-Volts DC.

  • Page 16: Service Plug

    Service Plug The high-voltage circuit is cut by removing service plug. (See page 15). HV Battery Pack High Voltage Safety System – Vehicle Shut Off (READY off) HV Battery Pack High Voltage Safety System – Vehicle On and Operational (READY on)

  • Page 17: Precaution To Be Observed When Dismantling The Vehicle

    Precaution to be observed when dismantling the vehicle WARNING: ・ Never assume that the Highlander is shut off simply because it is silent. ・ Assure that READY indicator is off. ・ After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.

  • Page 18: Spillage

    Spillage The Highlander contains the same common automotive fluids used in other Toyota vehicles, with the exception of NiMH electrolyte used in HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that causes damage to human tissues. The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked.

  • Page 19: Dismantling A Vehicle

    Dismantling a vehicle WARNING: ・ Never assume that the Highlander is shut off simply because it is silent. ・ Assure that READY indicator is off. ・ After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
  • Page 20 Do not rub your eyes but wash them with a dilute boric acid solution or a large amount of water and seek medical care. 7. Remove the parts by following the procedures which are similar to the Toyota vehicles with exception of HV battery. As for the removal of HV battery, please...

  • Page 22: Removal Of Hv Battery

    Removal of HV battery HV battery removal WARNING: ・ Never assume that the Highlander is shut off simply because it is silent. ・ Assure that READY indicator is off. ・ After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
  • Page 23 3. Remove the rear seat assemblies NO. 1 LH and RH (w/ Rear No. 2 seat). ① Remove the reclining hinge cover LH. ② Remove the 4 rear seat track covers. ③ Remove the 4 rear seat track bracket covers. ④...
  • Page 24 4. Remove the rear seat assemblies NO. 1 LH and RH (w/o Rear No. 2 seat). ① Move the rear seats LH and RH to the rear most position. ② Remove the 4 rear seat track bracket covers. ③ Remove the 4 bolts on the front side of the seat. ④...
  • Page 25 5. Remove the deck side trims LH and RH ① Remove the tonneau cover. ② Remove the deck board sub-assembly. ③ Remove the deck board sub-assembly NO. 2. ④ Remove the deck board sub-assembly NO. 3. ⑤ Remove the rear floor finish plate. ⑥...
  • Page 26 6. Remove the air intake cover (LH, RH and CENTER) a) Using a screwdriver with its tip taped, remove the 2 hole covers Hole cover from each air intake cover. b) Remove the 2 screws from each air intake cover. Release the 2 claws to remove the air intake covers LH, RH, and CENTER.
  • Page 27 8. Remove the bolt and rear seat belt assembly inner NO. 1. 9. Remove the 2 bolts and battery carrier bracket. (w/o Rear No. 2 seat) 10. Remove the 2 bolts on each battery carrier duct and remove the battery carrier ducts LH, RH, and CENTER.
  • Page 28 12. Remove the 3 frame wires. a) Remove the bolt and disconnect the connector. Remove frame wire No. 3. b) Remove the 2 nuts to remove the 2 frame wires from the SMR. 13. Disconnect the wires from the battery cooling blower, battery voltage sensor, and HV battery plug.
  • Page 29 Set a stopper on the end of the fork to prevent the battery unit from sliding down. Shackl Loop clutch Stopper 18. HV battery pack is recyclable. Contact your Toyota distributor as mentioned on HV Battery Caution Label or the nearest Toyota Dealer. (See the next page).

  • Page 30: Hv Battery Caution Label

    HV Battery Caution Label For U.S.A. For CANADA...

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