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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 40 (Hybrid Battery Control System - Service Information (2 Of 2)) >> Frame Wire >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 

    Refer to PRECAUTION [11/2023 - ]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2023 - ] 

  3. REMOVE NO. 2 INVERTER PROTECTOR 

    Refer to PROCEDURE - Step 9

  4. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.

    1. Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.
      NOTE:
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Insulate the disconnected terminals with insulating tape.
      • Do not touch the waterproof seal or terminals of the connector.
      GTY877747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 11

  6. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 12

  7. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 13

  8. DISCONNECT FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 14

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

    Refer to REMOVAL [12/2019 - ]

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

    Refer to REMOVAL [12/2019 - ]

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

    Refer to REMOVAL [12/2019 - ]

  12. REMOVE REAR NO. 2 SEAT ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  13. REMOVE REAR CONSOLE BOX ASSEMBLY (for Captain Seat Type) 

    Refer to REMOVAL [12/2019 - ]

  14. REMOVE FRONT DECK SIDE TRIM COVER RH 

    Refer to PROCEDURE - Step 41

  15. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 24

  16. REMOVE NO. 1 DECK SIDE TRIM COVER 

    HINT: 

    Use the same procedure as for the No. 2 deck side trim cover.

    Refer to PROCEDURE - Step 33

  17. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 24

  18. REMOVE COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR (w/ Rear Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 1

  19. REMOVE DECK TRIM POCKET COVER (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 35

  20. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 36

  21. REMOVE ROPE HOOK (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 37

  22. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH 

    Refer to PROCEDURE - Step 49

  23. DISCONNECT FLOOR UNDER WIRE 
    1. Disengage the 2 clamps.
      GTY880989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut to disconnect the HV floor under wire.
  24. SEPARATE FRONT FLOOR CARPET ASSEMBLY 

    See step  5

  25. REMOVE REAR FLOOR SILENCER 

    See step  6

  26. REMOVE NO. 10 HV BATTERY SHIELD PANEL 

    Refer to PROCEDURE - Step 20

  27. DISCONNECT FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 21

  28. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to REMOVAL [10/2022 - ]

  29. REMOVE EXHAUST MANIFOLD 

    Refer to REMOVAL [10/2022 - ]

  30. REMOVE FUEL TANK SUB-ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  31. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 34

  32. REMOVE ENGINE SERVICE COVER ASSEMBLY 
    1. Remove the 3 nuts, clip and engine service cover assembly.
      GTY880996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 3 EXHAUST PIPE SUPPORT BRACKET 
    1. GTY880992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 bolts and No. 3 exhaust pipe support bracket.

  34. REMOVE NO. 4 EXHAUST PIPE SUPPORT BRACKET 
    1. GTY935590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 bolts and No. 4 exhaust pipe support bracket.

  35. REMOVE REAR MAIN MUFFLER HEAT INSULATOR SUB-ASSEMBLY 
    1. Remove the 3 nuts and rear main muffler heat insulator sub-assembly.
      GTY881003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR 
    1. GTY881004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 3 nuts and front No. 1 floor heat insulator.

  37. REMOVE FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Insulate the disconnected connectors with insulating tape.

    1. Remove the nut and disconnect the transmission control cable assembly.
      GTY881019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and bolt to disconnect the air conditioning tube assembly.
      GTY881020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts.
      GTY880984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. for AWD:
      1. Remove the nut and clamp.
        GTY880985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the clamp.
        GTY880986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the 2 bolts and HV floor under wire from the rear traction motor with transaxle assembly.
        GTY938517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Waterproof Seal
        NOTE:
        • Do not damage the terminals, interlock connector or rear traction motor with transaxle assembly during disconnection.
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not allow any foreign matter or water to enter the rear traction motor with transaxle assembly.
        • Although the connector may feel loose, this is not due to a malfunction.
    5. Remove the nut and clamp.
      GTY942325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      NOTE:

      If the clamp is removed forcibly, the stud bolt may be damaged.

    6. Disengage the grommet and pull out the HV floor under wire from the floor panel hole.
    7. Remove the 3 nuts and clamp.
      GTY935587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the clamp is removed forcibly, the stud bolt may be damaged.

    8. Remove the nut, bolt and clamp.
      NOTE:

      If the clamp is removed forcibly, the stud bolt may be damaged.

      GTY880982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disengage the grommet and pull out the HV floor under wire from the floor panel hole.
      GTY880983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 2 nuts, bolt and 2 clamps.
      GTY880987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the clamps are removed forcibly, the stud bolts may be damaged.

    11. Disengage the 2 claws.
      GTY880978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Disengage the guide to remove the No. 1 terminal cap.
    13. Remove the nut.
      GTY880980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Disengage the 2 claws to disconnect the engine room main wire.
    15. Remove the 2 nuts and HV floor under wire.
      GTY881017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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