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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (1 Of 2)) >> HV Battery >> Removal [10/2022 - 11/2023] >> Procedure

Removal [10/2022 - 11/2023]: Procedure

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

    Refer to PRECAUTION [12/2019 - 11/2023]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [10/2022 - 11/2023]

  3. REMOVE NO. 2 INVERTER PROTECTOR 

    See step  9

  4. DISCONNECT ENGINE ROOM MAIN WIRE 

    Refer to PROCEDURE - Step 4

  5. REMOVE CONNECTOR COVER ASSEMBLY 

    See step  11

  6. CHECK TERMINAL VOLTAGE 

    See step  12

  7. INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

      Torque: 4.5 N.m (46 kgf/cm, 40 in.lbf) 

      GTY900150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
      NOTE:
      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
    2. Install the bolt (B).

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  8. CONNECT ENGINE ROOM MAIN WIRE 

    Refer to PROCEDURE - Step 31

  9. INSTALL NO. 2 INVERTER PROTECTOR 

    See step  17

  10. REMOVE BATTERY COOLING BLOWER ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  11. REMOVE NO. 3 FLOOR BOARD 
    1. Remove the No. 3 floor board.
      GTY935475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 FLOOR BOARD 
    1. Remove the No. 2 floor board.
      GTY880472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 FLOOR BOARD 
    1. Remove the No. 1 floor board.
      GTY880467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE REAR NO. 2 SEAT ASSEMBLY 

    Refer to REMOVAL [12/2019 - ]

  15. REMOVE FRONT DECK SIDE TRIM COVER LH 

    Refer to PROCEDURE - Step 31

  16. REMOVE FRONT DECK SIDE TRIM COVER RH 

    Refer to PROCEDURE - Step 41

  17. REMOVE CENTER PROTECTOR COVER 
    1. Remove the 3 clips (A).
      GTY872348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 clips (B) and center protector cover.
  18. REMOVE REAR SEAT SUB FLOOR PANEL ASSEMBLY 
    1. Disconnect the connector.
      GTY940413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and rear seat sub floor panel assembly.
  19. REMOVE VOLTAGE INVERTER ASSEMBLY (w/ Voltage Inverter) 

    Refer to REMOVAL [10/2022 - 11/2023]

  20. REMOVE NO. 10 HV BATTERY SHIELD PANEL 
    WARNING:

    Be sure to wear insulated gloves.

    1. for Captain Seat Type:
      1. Remove the 2 nuts and No. 3 console box mounting bracket from the HV battery.
        GTY893737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 No. 3 Console Box Mounting Bracket
        *2 No. 4 Console Box Mounting Bracket
      2. Remove the 2 nuts and No. 4 console box mounting bracket from the HV battery.
      3. Using the service plug grip, remove the battery cover lock striker.
        GTY910896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Service Plug Grip
        *2 Battery Cover Lock Striker
        *a Projection
        *b Turn
        *c Button

        HINT: 

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

      4. Remove the 2 nuts and No. 10 HV battery shield panel from the HV battery.
    2. for 60/40 Split Seat Type:
      1. Using the service plug grip, remove the battery cover lock striker.
        GTY905476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Service Plug Grip
        *2 Battery Cover Lock Striker
        *a Projection
        *b Turn
        *c Button

        HINT: 

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

      2. Remove the 6 nuts and No. 10 HV battery shield panel from the HV battery.
  21. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disconnect the 2 HV battery junction block assembly connectors.
      GTY922213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
      NOTE:

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

    2. Disengage the clamp.
    3. Disconnect the shield ground from the HV battery.
  22. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the 2 clamps.
      GTY880465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the floor wire connector.
    3. Disconnect the HV battery junction block assembly connector.
    4. 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.
    5. Disconnect the electric vehicle battery plug assembly connector.
      GTY935472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the 3 clamps to disconnect the floor wire.
  23. INSTALL NO. 10 HV BATTERY SHIELD PANEL 

    See step  6

  24. REMOVE HV BATTERY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 6 bolts.
      GTY880459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.
      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
      • Use cardboard or another similar material to protect the HV battery and vehicle body from damage.
      • Since the HV battery is very heavy, 2 people are needed to remove it. When removing the HV battery, be careful not to damage the parts around it.
      • When removing the HV battery from the vehicle, do not allow it to contact the vehicle.
      • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
      • Insulate the disconnected terminals or connectors with insulating tape.
      • If the HV battery has been struck or dropped, replace it.
    2. Prepare wooden blocks that will be used to pull out the HV battery.
      Wooden block 45 mm (1.7717 in.) x 45 mm (1.7717 in.) x 1000 mm (3.28 ft.)

      HINT: 

      The wooden blocks dimensions are an approximation.

      GTY880461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tilt the HV battery and place wooden blocks.
      GTY880460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Set the wooden blocks as shown in the illustration.
      GTY880455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the clip and No. 2 HV battery intake duct LH from the HV battery.
      GTY880456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the clamp.
      GTY880457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and disconnect the HV battery thermistor from the No. 2 HV battery intake duct RH.
      NOTE:
      • Be careful not to damage the HV battery thermistor.
      • When disconnecting the HV battery thermistor, hold it gently and pull it straight out.
    8. Remove the clip and No. 2 HV battery intake duct RH from the HV battery.
    9. Pull the HV battery to the rear of the vehicle as shown in the illustration.
      GTY880458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Pull the HV battery to the rear of the vehicle at the positions shown in the illustration.
      GTY880451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Using a suitable adaptor such as straps, remove the HV battery while tilting it.
      GTY880452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 10 HV BATTERY SHIELD PANEL 
    1. Remove the 6 nuts and No. 10 HV battery shield panel from the HV battery.
  26. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to PROCEDURE - Step 19

  27. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  28. REMOVE HYBRID BATTERY TERMINAL BLOCK 

    Refer to PROCEDURE - Step 20

  29. REMOVE NO. 6 HV BATTERY CARRIER BRACKET 

    See step  4

  30. REMOVE BATTERY VOLTAGE SENSOR 

    See step  5

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