Toyota Highlander GVU48 Series Dismantling Manual
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Toyota Highlander GVU48 Series Dismantling Manual

Mhu48/gvu48 series gasoline-electric hybrid synergy drive
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Gasoline-Electric
Hybrid Synergy Drive
Revised
MHU48/GVU48 Series

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Summary of Contents for Toyota Highlander GVU48 Series

  • Page 1 Gasoline-Electric Hybrid Synergy Drive Revised MHU48/GVU48 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Highlander gasoline-electric hybrid vehicles. Highlander hybrid dismantling procedures are similar to other non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Toyota Highlander hybrid, as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    Table of Contents About the Highlander Hybrid ........................1 Highlander Hybrid Identification ......................2 Exterior .................................3 Highlander Hybrid Identification (Continued)..................5 Interior................................5 Engine Compartment ............................6 Hybrid Component Locations & Descriptions..................7 Specifications ..............................8 Hybrid Synergy Drive Operation......................10 Vehicle Operation............................10 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery..............11 HV Battery Pack............................

  • Page 5: About The Highlander Hybrid

    About the Highlander Hybrid The Highlander hybrid continues into its 2 generation as a gasoline-electric hybrid vehicle. Hybrid Synergy Drive means that the vehicle contains a gasoline engine and electric motors for power. The two hybrid power sources are stored on board the vehicle: Gasoline stored in the fuel tank for the gasoline engine.

  • Page 6: Highlander Hybrid Identification

    Highlander Hybrid Identification In appearance, the 2008 model year Highlander hybrid is nearly identical to the conventional, non-hybrid Toyota Highlander. The Highlander hybrid 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 door pillar, and engine compartment.

  • Page 7: Exterior

    Highlander Hybrid Identification (Continued) Exterior logo on the back door. Highlander logo on the back door panel garnish. logo on each front fender. A radiator grill that is unique to the hybrid model.(2008 – 2010 Models) 2008 – 2010 Models: Exterior Driver Side View Exterior Front View Exterior Rear View...
  • Page 8 2011 Model: Exterior Driver Side View Exterior Front View Exterior Rear View Exterior Rear and Driver Side View...

  • Page 9: Highlander Hybrid Identification (Continued)

    Highlander Hybrid Identification (Continued) Interior Highlander Hybrid front door sill/scuff plate. (Standard on 2008 - 2010 Models and optional on 2011 Model) The 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. In place of a tachometer, a power meter showing kW output is used.

  • Page 10: Engine Compartment

    Highlander Hybrid Identification (Continued) Engine Compartment 3.3-liter aluminum alloy gasoline engine. (2008-2010 Models) 3.5-liter aluminum alloy gasoline engine. (2011 Model) High voltage inverter/converter assembly with logo on the cover. (2008-2010 Models) Engine with logo on the cover. (2011 Model) Orange colored high voltage power cables. Engine Compartment View (2008-2010 Models) Engine Compartment View (2011 Model) Power Cables...

  • Page 11: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description Engine Compartment 12 Volt A lead-acid battery that supplies power to the low voltage (2008 – 2010 Models) Auxiliary Battery devices. Cargo Area (2011 Model) Hybrid Vehicle Cabin Area, Mounted to 288 Volt Nickel Metal Hydride (NiMH) battery pack (HV) Battery Pack Cross Member under consisting of 30 low voltage (9.6 Volt) modules connected in...

  • Page 12: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 208 hp (156 kW), 3.3-liter Aluminum Alloy Engine (2008-2010 Models) 245 hp (183 kW), 3.5-liter Aluminum Alloy Engine (2011 Model) Electric Motors Front: 165 hp (123 kW), Permanent Magnet Motor Rear: 67 hp (50 kW), Permanent Magnet Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 288 Volt Sealed NiMH Battery...
  • Page 13 2011 Models...

  • Page 14: Hybrid Synergy Drive Operation

    Hybrid Synergy Drive Operation Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster.

  • Page 15: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The Highlander hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack • The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area floor pan cross member under the second row rear seat.

  • Page 16: Hv Battery Pack Recycling

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued) HV Battery Pack Recycling • The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV battery Caution Label (see page 36) or the nearest Toyota dealer. Auxiliary Battery •...

  • Page 17: High Voltage Safety

    High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored 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 18: Service Plug Grip

    High Voltage Safety (Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 15). 2008 – 2010 Models 2011 Model 12 Volt Auxiliary Battery 12 Volt Auxiliary Hybrid Vehicle Computer Volt DC Battery Compressor Electric...

  • Page 19: Precaution To Be Observed When Dismantling The Vehicle

    Precaution to be observed when dismantling the vehicle WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component.

  • Page 20: Spills

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

  • Page 21: Dismantling The Vehicle

    Dismantling the vehicle The following 2 pages contain general instructions for use when working on an Highlander hybrid. Read these instructions before proceeding to the HV battery removal instructions on page 18. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 22 3. Carry the removed service plug grip in your pocket to prevent other staff from accidentally reinstalling it while you are dismantling the vehicle. 4. Make other staff aware that a high-voltage system is being dismantled by using the following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 17). 5.
  • Page 23 6. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape. Before disconnecting or touching a bare high-voltage terminal, wear insulated gloves. 7. Check the HV battery and nearby area for leakage. If you find any liquid, it may be strong alkaline electrolyte.

  • Page 25: Removal Of Hv Battery

    Removal of HV battery WARNING: ・ Be sure to wear insulated gloves when handling high-voltage parts. ・ Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work. ・...
  • Page 26 Remove the service plug grip. (1) Remove the 5 clips and rear door scuff plate HV battery Remove the 2 clips and reclining hinge cover. Caution: Wear insulated gloves for the following 3 steps. (3) Raise the release handle of the service plug grip as shown in the illustration below.
  • Page 27 (2) Remove the 2 bolts. (3) Loosen the hose clamp and remove the intake air resonator. (4) Remove the 2 bolts and inverter reserve tank sub-assembly. (5) Remove the inverter cover 10 minutes or more after removal of the service plug grip. Caution: Wear insulated gloves.
  • Page 28 Insulating Tape (7) Insulate the removed terminal with insulating tape. Notice: Make sure that the terminal does not stick out from the insulating tape. (8) Remove the 12 bolts and inverter cover. Check the voltage at the terminals in the inspection point in the power control unit.
  • Page 29 7. Check the voltage at the terminals in the inspection point in the power control unit. (2011 Model) Remove the 11 clips and cool air intake duct seal. Remove the 2 bolts and disconnect 3 hose clamp. Remove the intake air resonator sub-assembly.
  • Page 30 Remove the 11 bolts and inverter terminal cover. Check the voltage at the terminals in the inspection point in the power control unit. Caution: Wear insulated gloves. To prevent serious injury or death, do not proceed with dismantling of the HV system until the voltage at the terminals in the inspection point is 0 V.
  • Page 31 11. Remove the left rear seat for the second row. (1) Disengage the 8 claws and remove the 2 rear seat track bracket covers. (2) Disengage the 4 claws and remove the rear outer track bracket cover. (3) Disengage the 5 claws and remove the rear inner track bracket cover.
  • Page 32 (4) Cut the seat lock cable assembly (with remote folding function). (5) Remove the 3 bolts on the rear side of the seat. (6) Remove the 2 bolts on the front side of the seat. (7) Remove the seat assembly. Caution: Do not cut wiring or wire harnesses when removing vehicle components.
  • Page 33 emove the right rear seat for the second row. (1) Disengage the 8 claws and remove the 2 rear seat track bracket covers. (2) Disengage the 4 claws and remove the rear outer track bracket cover. (3) Disengage the 5 claws and remove the rear inner track bracket cover.
  • Page 34 (4) Cut the seat lock cable assembly (with remote folding function). (5) Remove the 3 bolts on the rear side of the seat. (6) Remove the 2 bolts on the front side of the seat. (7) Remove the seat assembly. Caution: Do not cut wiring or wire harnesses when removing vehicle components.
  • Page 35 14. Remove the air intake cover LH. Release the claws using a screwdriver, and remove the 2 hole covers. Remove the 2 screws, then release the 2 claws and remove the air intake cover LH. 15. Remove the air intake cover RH. Release the claws using a screwdriver, and remove the 2 hole covers.
  • Page 36 Remove the 2 screws, then release the 2 claws and remove the center air intake cover. 17. Cut the floor carpe. 18. Turn back the floor carpe. 19. Remove the No. 1 HV battery tray. Hint: Remove any remaining butyl tape on the No. 1 HV battery tray and HV battery.
  • Page 37 20. Remove the No. 1 floor board. with Rear 3rd row Seat without Rear 3rd row Seat 21. Remove the No. 2 floor board. with Rear 3rd row Seat without Rear 3rd row Seat 22. Remove the No. 3 floor board. with Rear 3rd row Seat without Rear 3rd row Seat 23.
  • Page 38 24. Remove the 4 clips and floor spacer board. 25. Remove the 2 bolts and battery carrier duct 26. Disconnect the wire harness from the HV battery. 27. Remove the battery service hole cover. Using the service plug grip, remove the battery cover lock striker.
  • Page 39 28. Disconnect the 2 frame wires. Remove the 2 nuts to remove the 2 frame wires from the SMR. Caution: Wear insulated gloves. Notice: Insulate the terminals of the removed frame wire with insulating tape. 29. Remove the 11 bolts and battery room ventilation hose. 30.
  • Page 40 31. Pry either of the rear doors by operating the forklift to secure an opening for taking out the battery. 32. Insert the fork into the cabin to hang the HV battery unit. While maintaining clearance between the battery unit and the vehicle interior, take out the battery unit from the vehicle.

  • Page 41: Hv Battery Caution Label

    HV Battery Caution Label For U.S.A. For CANADA...
  • Page 42 For ECUADOR...

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