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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)) >> HV Relay Assembly >> 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 

    See step  4

  5. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 11

  6. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 12

  7. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  8. CONNECT ENGINE ROOM MAIN WIRE 

    See step  31

  9. INSTALL NO. 2 INVERTER PROTECTOR 

    Refer to PROCEDURE - Step 17

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

    Refer to REMOVAL [12/2019 - ]

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

    Refer to REMOVAL [12/2019 - ]

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

    Refer to REMOVAL [12/2019 - ]

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

    Refer to REMOVAL [12/2019 - ]

  14. SEPARATE FRONT FLOOR CARPET ASSEMBLY 

    See step  5

  15. REMOVE REAR FLOOR SILENCER 

    See step  6

  16. REMOVE NO. 10 HV BATTERY SHIELD PANEL 

    Refer to PROCEDURE - Step 20

  17. DISCONNECT FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 21

  18. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the clamp.
      GTY880478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the HV battery junction block assembly connector.
    3. w/ 1500w Voltage Inverter
      1. Disconnect the 2 HV battery junction block assembly connectors.
        NOTE:

        Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

        GTY930285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Shield Ground
      2. Using a screwdriver disengage the claw.
      3. Remove the nut and disconnect the shield ground.
  19. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disconnect the HV battery junction block assembly connector.
      GTY880479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected connectors with insulating tape.

    2. Disconnect the HV battery junction block assembly connector.
      NOTE:

      Insulate the disconnected connectors with insulating tape.

      GTY881130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the HV battery junction block assembly connector.
      GTY881127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 nuts and HV battery junction block assembly from the HV battery.
      NOTE:

      If the HV battery junction block assembly has been struck or dropped, replace it with a new one.

      GTY881147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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