Toyota 2006 HIGHLANDER User manual

2006 Model
© 2005 Toyota Motor Corporation
All rights reserved. This document may not be
altered without the written permission of Toyota Motor Corporation.
06Highlander Hybrid ERG REV A (07/12/06)

-i-
Foreword
In June 2005, Toyota released the Toyota Highlander gasoline-electric
hybrid vehicle in North America. Except where noted in this guide,
basic vehicle systems and features for the Highlander hybrid are the
same as those on the conventional, non-hybrid Highlander. To educate
and assist emergency responders in the safe handling of the Highlander
hybrid technology, Toyota published this Highlander hybrid
Emergency Response Guide.
High voltage electricity powers the electric motors, generator,
inverter/converter, and power steering. All other automotive electrical
devices such as the headlights, radio, and gauges are powered from a
separate 12-Volt battery. Numerous safeguards have been designed
into the Highlander hybrid to help ensure the high voltage,
approximately 288-Volt, Nickel Metal Hydride (NiMH) Hybrid
Vehicle (HV) battery pack is kept safe and secure in an accident.
The Highlander hybrid utilizes the following electrical systems:
•Maximum 650-Volts AC
•Nominal 288-Volts DC
•Nominal 42-Volts DC
•Nominal 12-Volts DC
Highlander hybrid features:
•Adoption of Hybrid Synergy Drive as the name for the Toyota
Gasoline - Electric Hybrid System.
•Hybrid Synergy Drive includes a boost converter in the inverter
assembly that boosts to 650-Volts the available voltage to the
electric motors.
•The high voltage hybrid vehicle battery pack rated at 288-Volts.
•A high voltage motor driven air conditioning compressor rated at
288-Volts.
•A high voltage Electric Power Steering (EPS) assist motor rated at
42-Volts.
•Body electrical system rated at 12-Volts negative chassis ground.
•Both two-wheel-drive (2WD) and four-wheel-drive intelligent
(4WD-i) configurations are available.
•4WD-i models include an additional 650-Volt electric motor to
drive the rear wheels.
•Supplemental Restraint System (SRS) - dual stage frontal airbags,
front seat mounted side airbags, side curtain airbags, and front seat
belt pretensioners.
High voltage electrical safety is an important factor in the emergency
handling of the Highlander Hybrid Synergy Drive system. It is
important to recognize and understand the disabling procedures and
warnings throughout the guide.
Additional topics contained in the guide include:
•Toyota Highlander hybrid identification.
•Major Hybrid Synergy Drive component locations and descriptions.
•Extrication, fire, recovery, and additional emergency response
information.
•Roadside assistance information.
2006 Model Year Highlander Hybrid
By following the information in this guide, emergency responders
should be able to safely perform a rescue involving the Toyota
Highlander hybrid vehicle.
NOTE:
Emergency Response Guides for select Toyota alternative fuel vehicles
may be viewed at http://techinfo.toyota.com.

-ii-
Table of Contents Page
About the Highlander Hybrid 1
Highlander Hybrid Identification 2
Hybrid Synergy Drive Component Locations & Descriptions 6
Hybrid Synergy Drive Operation 9
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery 10
High Voltage Safety 11
SRS Airbags & Seat Belt Pretensioners 13
Emergency Response 15
Extrication 15
Fire 18
Overhaul 19
Recovery/Recycling NiMH HV Battery Pack 19
Spills 20
First Aid 20
Submersion 21
Roadside Assistance 22

-1-
About the Highlander Hybrid
The Highlander hybrid is the first gasoline-electric hybrid Sports Utility
Vehicle (SUV) for Toyota. The gasoline-electric hybrid system has
been named Hybrid Synergy Drive. Hybrid Synergy Drive means that
the vehicle contains a gasoline engine and an electric motor for power.
Two energy sources are stored on board the vehicle:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery
pack for the electric motor.
The result of combining these two power sources is improved fuel
economy and reduced emissions. The gasoline engine also powers an
electric generator to recharge the battery pack; unlike a pure all electric
vehicle, the Highlander hybrid never needs to be recharged from an
external electric power source.
Depending on the driving conditions one or both sources are used to
power the vehicle. The following illustration demonstrates how the
Highlander hybrid operates in various driving modes.
On light acceleration at low speeds, the vehicle is powered by the
electric motor. The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the
gasoline engine. The gasoline engine is also used to recharge the
battery pack.
During full acceleration, such as climbing a hill, both the gasoline
engine and the electric motor power the vehicle.
During deceleration, such as braking, the vehicle regenerates the
kinetic energy from the front wheels to produce electricity that
recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor
are off, however the vehicle remains on and operational.

-2-
Highlander Hybrid Identification
In appearance, the 2006 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 and driver door post.
Example VIN: JTEGW21A840020208 (2WD)
JTEHW21A850011201 (4WD-i)
A Highlander hybrid is identified by the first 6 alphanumeric
characters as follows.
2WD: JTEGW2 / JTEDW2
4WD-i:JTEHW2 / JTEEW2
VIN Plate Locations

-3-
Highlander Hybrid Identification (Continued)
Exterior
logos the on rear
hatchback door.
Gasoline fuel filler door located on the driver side rear quarter panel.
Exterior Driver Side View
Exterior Front View Exterior Rear View
Exterior Rear and Driver Side View



-4-
Highlander Hybrid Identification (Continued)
Interior
Instrument cluster (speedometer, fuel gauge, warning lights) located in
the dash behind the steering wheel, is different than the one on the
conventional, non-hybrid Highlander.
In place of a tachometer, a power meter showing kW output is used.
NOTE:
If the vehicle is off, the instrument cluster will be “blacked out,” not
illuminated.
Interior View
Instrument Cluster View




-5-
Highlander Hybrid Identification (Continued)
Engine Compartment
3.3-liter aluminum alloy gasoline engine.
High voltage inverter/converter assembly with logos on the cover.
Logos on Cover
Engine Compartment View



-6-
Hybrid Synergy Drive Component Locations & Descriptions
Component Location Description
12-Volt 
Auxiliary
Battery
Engine
Compartment Lead-acid battery powers all low voltage electrical equipment.
Hybrid 
Vehicle
(HV) Battery
Pack
Cabin Area,
Mounted to Cross
Member located
Under Second
Row Seat
288-Volt Nickel Metal Hydride (NiMH)
battery pack consisting of 30 low voltage (9.6-
volt) modules connected in series.
Power 
Cables Under Carriage and Engine
Compartment
Orange colored power cables carry high
voltage Direct Current (DC) between the HV
battery pack, inverter/converter, and A/C
compressor. Also carries 3-phase Alternating
Current (AC) between inverter/converter,
motor, and generator.
Inverter/
Converter Engine Compartment Boosts and inverts the high voltage electricity from the HV battery pack to 3-phase AC
electricity that drives the electric motor. The
inverter/converter also converts AC electricity
from the electric generator and motor
(regenerative braking) to DC that recharges the
HV battery pack.
Gasoline 
Engine Engine Compartment Provides two functions: 1) powers vehicle; 2) powers generator to recharge the HV battery
pack. The engine is started and stopped under
control of the vehicle computer.
Front
Electric
Motor 
Engine
Compartment 3-phase high voltage AC permanent magnet electric motor contained in the front transaxle.
Used to power the front wheels.
Electric 
Generator Engine Compartment 3-phase high voltage AC generator contained in the front transaxle. Used to recharge the HV
battery pack.
A/C 
Compressor Engine Compartment 3-phase high voltage AC electrically driven motor compressor.
Hybrid Synergy Drive Components
*4WD-i models only
Components (Top View) and High Voltage Power Cables











11
*


-7-
Hybrid Synergy Drive Component Locations & Descriptions
(Continued)
Fuel Tank and Fuel Line Components
Rear Electric Motor
Component Location Description
EPS DC-DC
Converter 
Under Center
Console Converts 288-Volts from the HV battery pack to 42-Volt. Yellow-colored power cables
conduct the 42-Volt power underneath the
vehicle floor pan to the power steering rack via
the EPS ECU, located in the engine
compartment.
Fuel Tank 
and Fuel
Lines
Undercarriage,
Driver Side Fuel tank provides gasoline via a single fuel line to the engine. The fuel line is routed along
driver side under the floor pan.
Rear Electric
Motor
(4WD-i
Model Only)
Rear Sub-Frame 3-phase high voltage AC permanent magnet
electric motor contained in the rear transaxle
used to power the rear wheels.
11
11


-8-
Hybrid Synergy Drive Component Locations & Descriptions
(Continued)
Key Specifications:
Gasoline Engine: 208 hp, 3.3 liter Aluminum Alloy Engine
Electric Motors
Front:
Rear (4WD-i Only):
165 hp, Permanent Magnet Motor
67 hp, Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 288-Volt Sealed NiMH
Curb Weight
2WD:
4WD-i:
4,068 lbs / 1,845 kgs
4,244 lbs / 1,925 kgs
Fuel Tank: 17.2 gals / 65.0 liters
Fuel Economy
2WD:
4WD-i:
33 / 28 (City/Hwy) miles/gal
31 / 27 (City/Hwy) miles/gal
7.5 / 8.1 (City/Hwy) liters/100km
Frame Material: Steel unibody
Body Material: Steel panels
Seating Capacity:
7 Passenger
Steel Unibody

-9-
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. When lit, it informs the driver that the vehicle
is on and operational even though the gasoline engine may be off and
the engine compartment is silent.
Vehicle Operation
•With the Highlander hybrid, the gasoline engine may stop and start at any
time while the READY indicator is on.
•Never assume that the vehicle is shut off just because the engine is off.
Always look for the READY indicator status. The vehicle is shut off
when the READY indicator is off.
•The vehicle may be powered by:
1. The electric motor only.
2. The gasoline engine only.
3. A combination of both the electric motor and the gasoline engine.
•The vehicle computer determines the mode in which the vehicle operates
to improve fuel economy and reduce emissions. The driver cannot
manually select the mode.
Instrument cluster READY Indicator

-10-
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The Highlander hybrid contains a next generation high voltage, Hybrid
Vehicle (HV) battery pack and a low voltage auxiliary battery. The HV
battery pack contains non-spillable, sealed Nickel Metal Hydride
(NiMH) battery modules and the auxiliary battery is a typical
automotive lead-acid type.
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 rear seat.
The metal case is isolated from high voltage and concealed by a cover in
the cabin area.
•The HV battery pack consists of 30 low voltage (9.6-Volt) NiMH battery
modules connected in series to produce approximately 288-Volts. Each
NiMH battery module is non-spillable and sealed in a metal case.
•The electrolyte used in the NiMH battery module is an alkaline of
potassium and sodium hydroxide. The electrolyte is absorbed into the
battery cell plates and will form a gel that will not normally leak, even in
a collision.
•In the unlikely event the battery pack is overcharged, the modules vent
gases directly outside the vehicle through a vent hose.
HV Battery Pack
Battery pack voltage 288-Volts
Number of NiMH battery modules in the pack 30
NiMH battery module voltage 9.6-Volts
NiMH battery pack dimensions 25 x 43 x 7 in
(63 x 108 x 18 cm)
NiMH battery Pack weight 152.1 lbs
(69 kg)
Components Powered by the HV Battery Pack
•Front Electric Motor •Rear Electric Motor (with 4WD-i)
•Inverter/Converter •A/C Compressor
•Electric Generator •Power Cables
•Electric Power Steering
HV Battery Pack Recycling
•The HV battery pack is recyclable. Contact the nearest Toyota dealer or:
United States: [phone] Canada: (888) TOYOTA-8 or 896-6828
Auxiliary Battery
•The Highlander hybrid also contains a lead-acid 12-Volt battery. The 12-
Volt auxiliary battery powers the vehicle electrical system similar to a
conventional vehicle. As with other conventional vehicles, the auxiliary
battery is grounded (negative pole) to the metal chassis of the vehicle.
•The auxiliary battery is located in engine compartment area.
288-Volt HV Battery Pack 12-Volt Auxiliary Battery in Engine
Compartment.
HV Battery Pack Mounted in Cabin Area

-11-
High Voltage Safety
The HV battery pack powers the high voltage electrical system with
DC electricity. Positive and negative 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. The inverter creates
3-phase AC to power the motors. A set of 3 power cables is routed
from the inverter to each high voltage motor (electric motor, electric
generator, A/C compressor, and optional 4WD-i rear motor).
Occupants in the vehicle and emergency responders are separated from
high voltage electricity by the following system:
High Voltage Safety System
•A high voltage fuse provides short circuit protection in the HV battery
pack.
•Positive and negative high voltage power cables connected to the HV
battery pack are controlled by 12-Volt normally open relays . When the
vehicle is shut off, the relays stop electricity flow from the HV battery
pack.
WARNING:
High voltage electricity can cause death or serious injury from
severe burns or electric shock. To avoid death or serious injury
wait 5 minutes after disabling the vehicle to discharge high voltage
electricity, and do not touch, cut, or open any orange high voltage
power cable or high voltage component.
•Both positive and negative power cables are isolated from the metal
chassis, so there is no possibility of shock by touching the metal chassis.
•A ground fault monitor continuously monitors for high voltage leakage
to the metal chassis while the vehicle is running. If a malfunction is
detected, the vehicle computer will illuminate the master warning light
in the instrument cluster and indicate “CHECK HYBRID SYSTEM”
on the Multi-information Display.
•The HV battery pack relays will automatically open to stop electricity
flow in a collision sufficient to activate the SRS.
High Voltage Safety System – Vehicle Shut Off (READY-off)
High Voltage Safety System – Vehicle On and Operational (READY-on)



 
12-Volt
Battery
Electric
Motor
Inverter Boost
Converter
Hybrid
ECU
Electric
Motor
(
Rear
)
0.0
Volt
HV Battery Pack
HV Battery Module
HV Battery Pack
HV Battery Module
Electric
Motor
12-Volt
Battery
Inverter
650
Volt 288
Volt
Boost
Converter
288
Volt
Hybrid
ECU
Electric
Motor
(Rear)

-12-
High Voltage Safety (Continued)
The HV battery pack also powers a 288-Volt DC to 42-Volt DC converter for
the assist motor in the electric power steering (EPS). This DC-DC converter is
located under the center console . Both positive and negative 42-Volt cables
are contained within plastic yellow sheathing and are isolated from the
metal vehicle chassis.
NOTE:
42-Volt DC has a higher arc potential than 12-Volt DC.
HV Battery and DC-DC Converter Cable Routing
Note: Positive and negative power cables shown bundled as a single line



-13-
SRS Airbags & Seat Belt Pretensioners
Standard Equipment
•Electronic frontal impact sensors (2) are mounted in the engine
compartment .
•Front seat belt pretensioners are mounted near the base of the B-pillar .
•Frontal dual stage airbag for the driver is mounted in the steering
wheel hub.
•Frontal dual stage airbag for the front passenger is integrated into the
dashboard and deploys through the top of the dashboard.
•SRS computer is mounted on the floor pan underneath the center
console. It also contains an impact sensor.
Optional Side Airbag Package
•Front electronic side impact sensors (2) are mounted near the base of the
B-pillars .
•Rear electronic side impact sensors (2) are mounted near the base of the
C-pillars .
•Front seat side airbags are mounted in the front seats.
•Side curtain airbags are mounted along the outer edge inside the roof
rails.
NOTE:
The front seat side airbags and the side curtain airbags may deploy
independently of each other.
The front passenger occupant classification system may prohibit the
deployment of the frontal passenger airbag, front passenger side airbag,
and front passenger seat belt pretensioner.
WARNING:
The SRS airbags can cause death or serious injury by sudden deployment.
To avoid death or serious injury wait 90 seconds after disabling the
vehicle to allow the SRS backup power to discharge.
Frontal, Optional Front Seat Side, and Optional Side Curtain Airbags
Optional Front Seat Side and Side Curtain Airbag Identifiers
SRS CURTAIN
AIRBAG
SRS CURTAIN
AIRBAG
SRS SIDE AIRBAG

-14-
SRS Airbags & Seat Belt Pretensioners (Continued)
Standard Frontal Airbags and Seat Belt Pretensioners Optional Front Seat Side and Side Curtain Airbags Optional Side Curtain Airbag Inflator in Roof Rail









-15-
Emergency Response
On arrival, emergency responders should follow their standard
operating procedures for vehicle incidents. Emergencies involving the
Highlander hybrid may be handled like other automobiles except as
noted in these guidelines for Extrication, Fire, Overhaul, Recovery,
Spills, First Aid, and Submersion.
WARNING:
•Never assume the Highlander hybrid is shut off simply because it is
silent.
•Always observe the instrument cluster for the READY indicator
status to verify whether the vehicle is on or shut off. The vehicle is
shut off when the READY indicator is off.
•Failure to shut off the vehicle before emergency response procedures
are performed may result in death or serious injury from the sudden
deployment of the SRS or severe burns and electric shock from the
high voltage electrical system.
Extrication
•Immobilize Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the P(Park) position.
•Disable Vehicle
Performing either of the following two procedures will shut the
vehicle off and disable the HV battery pack, SRS, and gasoline fuel
pump.
Procedure #1
1. Turn the ignition key off.
2. Remove the key and place on dash. If the key cannot be removed,
disconnect the 12-Volt auxiliary battery in the engine
compartment.
NOTE:
Before disconnecting the 12-Volt auxiliary battery, reposition power
seats, lower windows, open door locks and fuel door as required.
Once the 12-Volt auxiliary battery is disconnected power controls
will not operate.
Chock Wheels Set Parking Brake
Shift Lever in Park Turn Ignition Key Off

-16-
Emergency Response (Continued)
Extrication (Continued)
Procedure #2 (Alternate if ignition key is inaccessible).
1. Disconnect the 12-Volt auxiliary battery in the engine
compartment.
2. Remove the fuse box cover.
3. Remove the IGCT No. 4 fuse (10A Red colored) in the engine
compartment junction block as illustrated. When in doubt, pull
all four fuses in the fuse block.
WARNING:
•High voltage electricity can cause death or serious injury from
severe burns or electric shock. To avoid death or serious injury
wait 5 minutes after disabling the vehicle to discharge high voltage
electricity, and do not touch, cut, or open any orange high voltage
power cable or high voltage component.
•The SRS airbags can cause death or serious injury by sudden
deployment. To avoid death or serious injury wait 90 seconds after
disabling the vehicle to allow the SRS backup power to discharge.
•If neither of the disabling procedures can be performed, proceed
with caution as there is no assurance that the high voltage
electrical system, SRS, or fuel pump are disabled.
Remote Hood Release Hood Latch Release
12-Volt Auxiliary Battery
Remove Junction Block Cover IGCT No. 4 Fuse Location
IGCT No.4 Fuse
Fuse box

-17-
Emergency Response (Continued)
Extrication (Continued)
•Stabilize Vehicle
Crib at (4) points directly under the front and rear pillars.
Do not place cribbing under the high voltage power cables, exhaust
system, or fuel system.
•Access Patients
Glass Removal
Use normal glass removal procedures as required.
SRS Awareness
Responders need to be cautious when working in close proximity
to undeployed airbags and seat belt pretensioners. Deployed front
dual stage airbags automatically ignite both stages within a
fraction of a second.
Door Removal/Displacement
Doors can be removed by conventional rescue tools such as hand,
electric, and hydraulic. In certain situations, it may be easier to
pry back the body to expose and unbolt the hinges.
Roof Removal
The vehicle may contain optional side curtain airbags. If
equipped and undeployed, it is not recommend to remove or to
displace the roof. Optional side curtain airbags may be identified
as illustrated.
Dash Displacement
The vehicle may contain optional side curtain airbags. When
equipped, do not remove or displace the roof during a dash
displacement to avoid cutting into undeployed airbags or
inflators. As an alternative, dash displacement may be performed
by using a Modified Dash Roll.
If not equipped with the optional side curtain airbags, displace the
dash by using a conventional dash roll or Modified Dash Roll.
Cribbing Points Underbody View
Optional Front Seat Side and Side Curtain Airbag Identifiers
SRS
CURTAIN
AIRBAG
SRS CURTAIN
AIRBAG
SRS SIDE AIRBAG
Cribbing Points