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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> Hybrid Battery Control System (Service Information) >> HV Battery >> Removal [02/2014 - 11/2016] >> Procedure

Removal [02/2014 - 11/2016]: Procedure

  1. PRECAUTION 

    Refer to PRECAUTION [02/2014 - 11/2016]

  2. CHECK FOR DTC 
    1. Check for DTCs.

      Refer to DTC CHECK / CLEAR [02/2014 - 11/2016]

      NOTE:

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before removing or installing an HV battery module. If this DTC is output, perform troubleshooting for this DTC first.

  3. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [02/2014 - ] 

  4. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 1

  5. REMOVE RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 2

  6. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3

  7. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  8. REMOVE INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 9

  9. REMOVE NO. 3 INVERTER BRACKET 

    See step  6

  10. REMOVE INVERTER TERMINAL COVER 

    See step  9

  11. CHECK TERMINAL VOLTAGE 

    See step  10

  12. INSTALL INVERTER TERMINAL COVER 

    See step  18

  13. INSTALL NO. 3 INVERTER BRACKET 

    See step  21

  14. INSTALL INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 5

  15. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  16. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  17. INSTALL RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  18. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 6

  19. REMOVE REAR NO. 1 SEAT ASSEMBLY (for Captain Seat Type) 

    Refer to REMOVAL [02/2014 - ]

  20. REMOVE REAR NO. 1 SEAT ASSEMBLY (for 60/40 Split Seat Type LH Side) 

    Refer to REMOVAL [02/2014 - ]

  21. REMOVE REAR NO. 1 SEAT ASSEMBLY (for 60/40 Split Seat Type RH Side) 

    Refer to REMOVAL [02/2014 - ]

  22. REMOVE REAR NO. 2 SEAT ASSEMBLY 

    Refer to REMOVAL [02/2014 - 11/2016]

  23. REMOVE AIR INTAKE COVER 

    See step  1

  24. SEPARATE FRONT FLOOR CARPET ASSEMBLY 
    1. Turn back the front floor carpet assembly.
  25. REMOVE NO. 1 FLOOR BOARD 
    1. Remove the No. 1 floor board.
      GTY450656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 FLOOR BOARD 
    1. Remove the No. 2 floor board.
      GTY424953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 3 FLOOR BOARD 
    1. Remove the No. 3 floor board.
      GTY424952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HYBRID BATTERY COVER SHEET 
    1. Remove the hybrid battery cover sheet from the HV battery.
      GTY424811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE BATTERY CARRIER DUCT 
    1. Remove the 2 nuts and battery carrier duct from the HV battery (for LH Side).
      GTY441049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and battery carrier duct from the HV battery (for Center).
      GTY441047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts and battery carrier duct from the HV battery (for RH Side).
      GTY441050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL 
    WARNING:

    Wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker from the No. 8 hybrid vehicle battery shield panel.
      GTY428072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *a Projection
      *b Button
      *c Turn

      HINT: 

      Insert the projection of the service plug grip, turn the button of the battery cover lock striker counterclockwise, and release the lock.

    2. Remove the 3 nuts and No. 8 hybrid vehicle battery shield panel from the upper hybrid vehicle battery cover sub-assembly.
      GTY424949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE REAR BODY WIRE 
    1. Disconnect the 4 rear body wire connectors.
      GTY450653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 5 clamps and remove the rear body wire from the upper hybrid vehicle battery cover sub-assembly.
  32. REMOVE UPPER HYBRID VEHICLE BATTERY COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Remove the 3 nuts and 3 wire harness clamp brackets from the upper hybrid vehicle battery cover sub-assembly.
      GTY424956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp from the upper hybrid vehicle battery cover sub-assembly.
      GTY450654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 6 clamps.
      GTY424955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 wire harness clamps from the upper hybrid vehicle battery cover sub-assembly.
      GTY450622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using the service plug grip, remove the battery cover lock striker from the upper hybrid vehicle battery cover sub-assembly.
      GTY431812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *a Projection
      *b Button
      *c Turn

      HINT: 

      Insert the projection of the service plug grip, turn the button of the battery cover lock striker counterclockwise, and release the lock.

    6. Remove the 25 bolts, 6 nuts and upper hybrid vehicle battery cover sub-assembly.
      GTY424816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE BATTERY VOLTAGE SENSOR 

    See step  3

  34. REMOVE HV BATTERY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:
    • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
    • Use cardboard or other similar material to protect the HV battery module and vehicle body from damage.
    • When removing an HV battery module from the vehicle, do not allow it to contact the vehicle.
    • When removing/installing/moving an HV battery module, make sure not to tilt it more than 80°.
    • When moving an HV battery module, make sure to use an engine lifter.
    • Insulate the disconnected terminals or connectors with insulating tape.

    HINT: 

    Replace the lower hybrid battery carrier panel if any liquids and foreign matter have collected in the lower hybrid battery carrier panel.

    1. Remove the HV battery module (for LH Side).
      1. Disconnect the No. 2 hybrid vehicle battery pack cable connector.
        GTY424942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Insulate the disconnected connectors with insulating tape.

      2. Open the terminal cover.
        GTY424944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using an insulated tool, remove the nut and disconnect the electric vehicle battery plug assembly cable from the HV battery module (for LH Side).
        NOTE:
        • Do not use a universal joint with a socket extension. Using a universal joint may cause the socket extension to drop and create a short circuit.
        • Insulate the disconnected terminal with insulating tape.
      4. Close the terminal cover.
        NOTE:

        Make sure that the terminal cover is closed securely.

      5. Open the terminal cover.
        GTY424943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Using an insulated tool, remove the nut and disconnect the HV battery module (for Center) cable from the HV battery module (for LH Side).
        NOTE:
        • Do not use a universal joint with a socket extension. Using a universal joint may cause the socket extension to drop and create a short circuit.
        • Insulate the disconnected terminal with insulating tape.
      7. Close the terminal cover.
        NOTE:

        Make sure that the terminal cover is closed securely.

      8. Disconnect the HV battery module (for LH side) cable connector.
        GTY424946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Insulate the disconnected connectors with insulating tape.

      9. Install the 2 battery clamps to the HV battery module (for LH Side).
        NOTE:

        Insert the ends of the 2 battery clamps into the installation holes. Pull the 2 battery clamps upward to securely install them.

        GTY428149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Battery Clamp (G9298-48010)
      10. Remove the HV battery module (for LH Side).
      11. Remove the 2 battery clamps from the HV battery module (for LH Side).
    2. Remove the HV battery module (for Center).
      1. Disengage the 2 clamps.
        GTY424947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the No. 2 hybrid battery pack wire connector.
        GTY450652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disengage the clamp.
      4. Disconnect the hybrid battery junction block assembly connector.
        GTY424948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Insulate the disconnected connectors with insulating tape.

      5. Disconnect the HV battery module (for RH Side) cable connector.
        GTY450649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Insulate the disconnected connectors with insulating tape.

      6. Disengage the clamp.
      7. Install the 2 battery clamps to the HV battery module (for Center).
        GTY436264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Battery Clamp (G9298-48010)
        NOTE:

        Insert the ends of the 2 battery clamps into the installation holes. Pull the 2 battery clamps upward to securely install them.

      8. Remove the HV battery module (for Center).
      9. Remove the 2 battery clamps from the HV battery module (for Center).
    3. Remove the HV battery module (for RH Side).
      1. Disconnect the HV battery module (for RH Side) cable connector.
        GTY424934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the clamp.
      3. Disconnect the hybrid battery junction block assembly connector.
        GTY424933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:

        Insulate the disconnected connectors with insulating tape.

      4. Open the terminal cover.
        GTY454145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Using an insulated tool, remove the nut and disconnect the No. 2 hybrid vehicle battery pack cable from the HV battery module (for RH Side).
        NOTE:
        • Do not use a universal joint with a socket extension. Using a universal joint may cause the socket extension to drop and create a short circuit.
        • Insulate the disconnected terminal with insulating tape.
      6. Close the terminal cover.
        NOTE:

        Make sure that the terminal cover is closed securely.

      7. Install the 2 battery clamps to the HV battery module (for RH Side).
        GTY452998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Battery Clamp (G9298-48010)
        NOTE:

        Insert the ends of the 2 battery clamps into the installation holes. Pull the 2 battery clamps upward to securely install them.

      8. Remove the HV battery module (for RH Side).
      9. Remove the 2 battery clamps from the HV battery module (for RH Side).
  35. REMOVE BATTERY COOLING BLOWER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    HINT: 

    Perform this procedure only when replacement of the lower hybrid battery carrier panel is necessary.

    1. Remove the 9 nuts and 3 battery cooling blower assemblies.
      GTY424932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be sure not to touch the fan part of the battery cooling blower assembly.
      • Do not lift the battery cooling blower assembly using the wire harness.
  36. REMOVE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    HINT: 

    Perform this procedure only when replacement of the lower hybrid battery carrier panel is necessary.

    1. Disengage the clamp.
      GTY424935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the electric vehicle battery plug assembly connector.
      GTY424939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the clamp.
    4. Remove the bolt and electric vehicle battery plug assembly from the lower hybrid battery carrier panel as shown in the illustration.
      GTY450650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    HINT: 

    Perform this procedure only when replacement of the lower hybrid battery carrier panel is necessary.

    1. Using an insulated tool, remove the 2 nuts and disconnect the No. 6 floor wire from the hybrid battery junction block assembly.
      NOTE:

      Insulate the disconnected terminals with insulating tape.

      GTY424937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 hybrid battery junction block assembly connectors.
      GTY424938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 nuts and hybrid battery junction block assembly from the lower hybrid battery carrier panel.
      GTY424936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 2 HYBRID VEHICLE BATTERY PACK CABLE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    HINT: 

    Perform this procedure only when replacement of the lower hybrid battery carrier panel is necessary.

    1. Remove the No. 2 hybrid vehicle battery pack cable from the lower hybrid battery carrier panel.
      GTY424963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 HYBRID BATTERY PACK WIRE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    HINT: 

    Perform this procedure only when replacement of the lower hybrid battery carrier panel is necessary.

    1. Disengage the 4 clamps.
      GTY450655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps.
      GTY424959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 2 hybrid battery pack wire connector.
      GTY424962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the clamp and remove the No. 2 hybrid battery pack wire.
  40. REMOVE LOWER HYBRID BATTERY CARRIER PANEL 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    HINT: 

    Perform this procedure only when replacement of the lower hybrid battery carrier panel is necessary.

    1. Remove the 2 wire harness clamps from the lower hybrid battery carrier panel.
      GTY424961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness clamp bracket from the lower hybrid battery carrier panel.
      GTY424771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the lower hybrid battery carrier panel from the vehicle.
      GTY433211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the No. 3 hybrid vehicle battery carrier sheet from the lower hybrid battery carrier panel.
      GTY424964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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