Toyota 2014 HIGHLANDER GVU58 Series Dismantling Manual
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Toyota 2014 HIGHLANDER GVU58 Series Dismantling Manual

Toyota 2014 HIGHLANDER GVU58 Series Dismantling Manual

Gvu58 series gasoline-electric hybrid synergy drive
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HIGHLANDER
Hybrid
Gasoline-Electric
Hybrid Synergy Drive
GVU58 Series

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Summary of Contents for Toyota 2014 HIGHLANDER GVU58 Series

  • Page 1 HIGHLANDER Hybrid Gasoline-Electric Hybrid Synergy Drive GVU58 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota HIGHLANDER Hybrid 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 Interior................................4 Engine Compartment ............................5 Hybrid Component Locations & Descriptions...................6 Specifications ..............................7 Hybrid Synergy Drive Operation........................8 Vehicle Operation............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery................9 HV Battery Pack............................9 Components Powered by the HV Battery Pack.....................9 HV Battery Pack Recycling .........................10 Auxiliary Battery ............................10...

  • Page 5: About The Highlander Hybrid

    About the HIGHLANDER Hybrid The HIGHLANDER Hybrid continues into its 3 generation as a gasoline-electric hybrid vehicle. Hybrid Synergy Drive means that the vehicle contains a gasoline engine and two electric motors for power. The two hybrid power sources are stored on board the vehicle: 1.

  • Page 6: Highlander Hybrid Identification

    HIGHLANDER Hybrid Identification In appearance, the 2014 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, right side floor and on the driver side B pillar.

  • Page 7: Exterior

    HIGHLANDER Hybrid Identification (Continued) Exterior logos on the back door. logo on the driver and front passenger door. Gasoline fuel filler door located on the driver side rear quarter panel. Exterior Front and Driver Side View Exterior Rear and Driver Side View...

  • Page 8: Interior

    HIGHLANDER Hybrid Identification (Continued) Interior The instrument cluster (READY indicator, and warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid HIGHLANDER. Hint: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated. Interior View READY Indicator Monochrome Type Multi-information Display...

  • Page 9: Engine Compartment

    HIGHLANDER Hybrid Identification (Continued) Engine Compartment 3.5-liter aluminum alloy gasoline engine. Logo on the plastic engine cover. Orange colored high voltage power cables. Engine Compartment View Power Cables...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description 12 Volts Auxiliary Left Side of A lead-acid battery that supplies power to the low voltage Battery Trunk devices. Hybrid Vehicle Cabin Area, 288 Volts Nickel Metal Hydride (NiMH) battery pack (HV) Battery Mounted to Cross consisting of 30 low voltage (9.6 Volts) modules connected Pack...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 231 hp (172.3 kW), 3.5-liter Aluminum Alloy Engine 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 V Sealed NiMH Battery Curb Weight: 4,784 - 4,861 lbs/2,170 - 2,205 kg Fuel Tank: 17.2 gals/65 liters...

  • Page 12: 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 13: 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 seats.

  • Page 14: 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 29) or the nearest Toyota dealer. Auxiliary Battery •...

  • Page 15: 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 16: 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). Volt DC Hybrid Vehicle Computer Compressor Electric Electric Inverter/ Motor Generator Converter (Rear) 12 Volts Electric Auxiliary Volt DC Motor Battery (Front)

  • Page 17: 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 18: 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.

  • Page 19: Dismantling The Vehicle

    Dismantling the vehicle The following 3 pages contain general instructions for use when working on a HIGHLANDER Hybrid. Read these instructions before proceeding to the HV battery removal instructions on page WARNING: The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 20 3. Remove the service plug grip. Caution: ・ Wear insulated gloves. ・ Remove the service plug grip to interrupt the high voltage circuit. ・ Keep the removed service plug grip in your pocket to prevent other staff from accidentally reinstalling it while you are dismantling the vehicle. ・...
  • Page 21 Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 10. With the exception of the HV battery, remove parts by following procedures which are similar to conventional Toyota vehicles. For the removal of the HV battery, refer to the following pages.

  • Page 23: 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 24 4. REMOVE AUXILIARY BATTERY (1) Open the auxiliary battery terminal cap. (2) Loosen the nut and disconnect the cable from the positive (+) auxiliary battery terminal. (3) Remove the nut and bolt. (4) Remove the battery clamp sub-assembly from the auxiliary battery. (5) Disconnect the battery hose from the auxiliary battery.
  • Page 25 (1) Wear insulated gloves and remove the service plug grip after sliding the lever of the service plug grip as shown in the illustration. 6. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH (1) Remove the 2 clips and radiator side deflector seal LH.
  • Page 26 10. REMOVE INLET NO. 2 AIR CLEANER (1) Remove the 2 bolts. (2) Remove the inlet No. 2 air cleaner from the inlet No. 1 air cleaner. 11. REMOVE NO. 3 INVERTER BRACKET (1) Remove the bolt, nut and No. 3 inverter bracket.
  • Page 27 Hint: Use a measuring range of DC 750 V or more on the voltmeter. 14. REMOVE REAR NO. 1 SEAT ASSEMBLY (for Captain Seat Type and 60/40 Split Seat Type LH Side) Hint: Use the same procedure for the RH side and LH side (for captain seat type).
  • Page 28 (4) Disengage the 3 clips and remove the rear outer seat track bracket cover. Using a screwdriver, disengage the 2 claws to open the 2 caps for the rear door scuff panel Remove the 2 bolts and disengage the 2 guides to remove the rear door scuff panel LH.
  • Page 29 Disengage the 6 claws, 2 clips and 2 guides to remove the rear door scuff plate LH. (10) Remove the rear seat headrest assembly. (11) Disconnect the connector (w/ seat heater system). (12) Remove the 3 bolts on the rear side of the rear No.
  • Page 30 (3) Disengage the 2 clips and remove the rear inner seat track bracket cover. (4) Disengage the 3 clips and remove the rear outer seat track bracket cover. (5) Remove the rear door scuff plate. Hint: Use the same procedure as for the LH side. (6) Remove the rear seat headrest assembly.
  • Page 31 16. REMOVE REAR NO. 2 SEAT ASSEMBLY (1) Fold the rear No. 2 seatback assembly RH forward. (2) Using a clip remover, remove the 7 clips. (3) Remove the nut and disengage the 4 claws, 2 clips and 2 guides to remove the rear deck floor box.
  • Page 32 (5) Remove the rear No. 2 seat inner belt sub-assembly from the rubber band of the rear seat cushion assembly as shown in the illustration. (6) Remove the bolt to disconnect the floor anchor of the rear No. 2 seat inner belt assembly RH. (7) Remove the rear No.
  • Page 33 (8) Disengage the 2 claws and 2 guides as indicated by the arrows, in the order shown in the illustration to remove the rear seat leg cover LH. (9) Disengage the 2 claws and 2 guides as indicated by the arrows, in the order shown in the illustration to remove the rear seat leg cover.
  • Page 34 (12) Remove the 3 bolts on the rear side of the rear No. 2 seat assembly. (13) Remove the rear No. 2 seat assembly. 17. REMOVE AIR INTAKE COVER Hint: ・ Use the same procedure as for the center and RH side.
  • Page 35 20. REMOVE NO. 2 FLOOR BOARD (1) Remove the No. 2 floor board. 21. REMOVE NO. 3 FLOOR BOARD (1) Remove the No. 3 floor board. 22. REMOVE HYBRID BATTERY COVER SHEET (1) Remove the hybrid battery cover sheet from the HV battery.
  • Page 36 24. REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL Caution: Wear insulated gloves. (1) Using the service plug grip, remove the battery cover lock striker from the No. 8 hybrid vehicle battery shield panel. Text in Illustration Service Plug Grip Battery Cover Lock Striker Projection Button...
  • Page 37 (2) Disengage the clamp from the upper hybrid vehicle battery cover sub-assembly. (3) Disengage the 6 clamps. (4) Remove the 3 wire harness clamps from the upper hybrid vehicle battery cover sub-assembly. (5) Using the service plug grip, remove the battery cover lock striker from the upper hybrid vehicle battery cover sub-assembly.
  • Page 38 (6) Remove the 25 bolts, 6 nuts and upper hybrid vehicle battery cover sub-assembly. 27. REMOVE BATTERY VOLTAGE SENSOR CONNECTOR Caution: Be sure to wear insulated gloves and protective goggles. (1) Disconnect the 3 battery voltage sensor connectors. Notice: Insulate the disconnected high voltage connectors with insulating tape. 28.
  • Page 39 (1) Remove the HV battery module (for LH side). Disconnect the No. 2 hybrid vehicle battery pack cable connector. Notice: Insulate the disconnected connectors with insulating tape. Open the terminal cover. Using an insulated tool, remove the nut and disconnect the electric vehicle battery plug assembly cable from the HV battery module (for LH side).
  • Page 40 Disconnect the HV battery module (for LH side) cable connector. Notice: Insulate the disconnected connectors with insulating tape. Install the 2 battery clamps or ropes to the HV battery module (for LH side). Remove the HV battery module (for LH side).
  • Page 41 Disconnect the HV battery module (for RH side) cable connector. Notice: Insulate the disconnected connectors with insulating tape. Disengage the clamp. Install the 2 battery clamps or ropes to the HV battery module (for center). Remove the HV battery module (for center).
  • Page 42 Remove the HV battery module (for RH side). 29. The HV battery pack is recyclable. Contact your Toyota distributor (if included on the HV battery caution label) or contact the nearest Toyota dealer (see next page for samples of the HV battery caution label).

  • Page 43: Hv Battery Caution Label

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

This manual is also suitable for:

2014 highlander hybrid

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