Toyota Highlander GVU48 Series User manual

Gasoline-Electric
Hybrid Synergy Drive
Revised
MHU48/GVU48 Series

ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Toyota Highlander
gasoline-electric hybrid vehicles. Highlander hybrid dismantling procedures are similar to other
non-hybrid Toyota vehicles with the exception of the high voltage electrical system. It is important to
recognize and understand the high voltage electrical system features and specifications of the Toyota
Highlander hybrid, as they may not be familiar to dismantlers.
High voltage electricity powers theA/C compressor, electric motors, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary 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 NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
• Toyota Highlander hybrid identification.
• Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle Highlander hybrid-electric
vehicles as safely as the dismantling of a conventional non-hybrid automobile.
©2011 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

iii
Table of Contents
About the Highlander Hybrid ..................................................................................................................1
Highlander Hybrid Identification............................................................................................................2
Exterior .........................................................................................................................................................3
Highlander Hybrid Identification (Continued).......................................................................................5
Interior...........................................................................................................................................................5
Engine Compartment....................................................................................................................................6
Hybrid Component Locations & Descriptions........................................................................................7
Specifications................................................................................................................................................8
Hybrid Synergy Drive Operation...........................................................................................................10
Vehicle Operation........................................................................................................................................10
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery...................................................................11
HV Battery Pack..........................................................................................................................................11
Components Powered by the HV Battery Pack...........................................................................................11
HV Battery Pack Recycling.........................................................................................................................12
Auxiliary Battery..........................................................................................................................................12
High Voltage Safety .................................................................................................................................13
High Voltage Safety System........................................................................................................................13
Service Plug Grip........................................................................................................................................14
Precaution to be observed when dismantling the vehicle.....................................................................15
Necessary Items.........................................................................................................................................15
Spills..........................................................................................................................................................16
Dismantling the vehicle...........................................................................................................................17
Removal of HV battery ...........................................................................................................................21
HV Battery Caution Label ...........................................................................................................................37

About the Highlander Hybrid
The Highlander hybrid continues into its 2nd generation as a gasoline-electric hybrid vehicle.
Hybrid Synergy Drive means that the vehicle contains a gasoline engine and electric motors for
power. The two hybrid power 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.
nDuring light acceleration at low speeds, the vehicle is powered by the electric motor. The
gasoline engine is shut off.
oDuring normal driving, the vehicle is powered mainly by the gasoline engine. The gasoline
engine also powers the generator to recharge the battery pack.
pDuring full acceleration, such as climbing a hill, both the gasoline engine and the electric
motor power the vehicle.
qDuring deceleration, such as when braking, the vehicle regenerates the kinetic energy from
the wheels to produce electricity that recharges the battery pack.
rWhile the vehicle is stopped, the gasoline engine and electric motor are off, however the
vehicle remains on and operational.
r
1

Highlander Hybrid Identification
In appearance, the 2008 model year 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, driver door pillar, and engine compartment.
Example VIN: JTEEW41AF82020211 (2008 - 2010 Models)
JTEBC3EHF82020211 (2011 Model)
JTEBD3EHF82020211 (2011 Model)
A Highlander hybrid is identified by the first 6 alphanumeric characters
JTEEW4, JTEBC3 or JTEBD3.
Left Side Windshield Driver Side B Pillar
2

Highlander Hybrid Identification (Continued)
Exterior
nlogo on the back door.
oHighlander logo on the back door panel garnish.
plogo on each front fender.
qA radiator grill that is unique to the hybrid model.(2008 – 2010 Models)
2008 – 2010 Models:
Exterior Driver Side View
Exterior Front View Exterior Rear View
Exterior Rear and Driver Side View
p
q
p
p
n
o
n
o
3

2011 Model:
Exterior Driver Side View
Exterior Front View Exterior Rear View
Exterior Rear and Driver Side View
p
p
n
o
p
n
o
4

Highlander Hybrid Identification (Continued)
Interior
rHighlander Hybrid front door sill/scuff plate. (Standard on 2008 - 2010 Models and optional on 2011
Model)
sThe 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.
tIn place of a tachometer, a power meter showing kW output is used.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.
Interior View of Front Door Sill/Scuff Plate
Instrument Cluster View
t
r
t
s
5

Highlander Hybrid Identification (Continued)
Engine Compartment
u3.3-liter aluminum alloy gasoline engine. (2008-2010 Models)
3.5-liter aluminum alloy gasoline engine. (2011 Model)
vHigh voltage inverter/converter assembly with logo on the cover. (2008-2010 Models)
Engine with logo on the cover. (2011 Model)
wOrange colored high voltage power cables.
Engine Compartment View (2008-2010 Models) Engine Compartment View (2011 Model)
Power Cables
vv
u
u
w
6

7
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt n
Auxiliary Battery Engine Compartment
(2008 – 2010 Models)
Cargo Area (2011
Model)
A lead-acid battery that supplies power to the low voltage
devices.
Hybrid oVehicle
(HV) Battery Pack Cabin Area, Mounted to Cross Member 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 pCables Undercarriage and
Engine Compartment Orange colored power cables carry high voltage Direct Current (DC) between the HV battery pack,
inverter/converter, and A/C compressor. These cables also
carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motors, and generator.
Inverter/
Converter qEngine Compartment Boosts and inverts the high voltage electricity from the HV battery pack to 3-phase AC electricity that drives the electric
motors. The inverter/converter also converts AC electricity
from the electric generator and electric motors (regenerative
braking) to DC that recharges the HV battery pack.
Gasoline r
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 Electrics
Motor Engine Compartment 3-phase high voltage AC permanent magnet electric motor contained in the front transaxle. It is used to power the
front wheels.
Electric t
Generator Engine Compartment 3-phase high voltageAC generator that is contained in the transaxle and recharges the HV battery pack.
A/C Compressor
(with Inverter) uEngine Compartment 3-phase high voltage AC electrically driven motor compressor.
Fuel Tank and Fuel
Line vUndercarriage and Center The fuel tank provides gasoline via a fuel line to the engine. The fuel line is routed under the center of vehicle.
Rear Electric
Motor wRear Sub-Frame 3-phase high voltage AC permanent magnet electric motor contained in the rear transaxle. It is used to power the rear
wheels.
*Numbers in the component column apply to the illustrations on the following page.

Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 208 hp (156 kW), 3.3-literAluminum Alloy Engine (2008-2010 Models)
245 hp (183 kW), 3.5-liter Aluminum Alloy Engine (2011 Model)
Electric Motors
Front:
Rear:
165 hp (123 kW), Permanent Magnet Motor
67 h
p
(
50 kW
)
, Permanent Ma
g
net Moto
r
Transmission: Automatic Only (electrically controlled continuously variable transaxle)
HV Batter
y
: 288 Volt Sealed NiMH Batter
y
Curb Weight: 4,641 lbs/2,105 kg (2008-2010 Models)
4,762 lbs/ 2,160 kg (2011 Model)
Fuel Tank: 17.2 gals/65.0 liters
Fuel Economy
Ratings: 27/25 (City/Hwy) miles/gal
8.6/9.4
(
Cit
y
/Hw
y)
liters/100 k
m
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 standard/7 with optional 3rd row seating (2008-2010 Models)
7 passengers (2011 Model)
2008-2010 Models:
o
n
q
p
ur
ts
w
p
v
8

2011 Models
9
n
p
o
w
q
r
ts
u
p
v

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 illuminated, 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.
Instrument Cluster READY Indicator
10

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The Highlander hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed
Nickel Metal Hydride (NiMH) battery modules.
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 carpet 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 mixture of potassium and sodium
hydroxide. The electrolyte is absorbed into the battery cell plates and will not normally leak, even
in a collision.
• In the unlikely event that the battery pack is overcharged, the modules vent gases directly outside the
vehicle through a vent hose.
HV Battery Pack
Battery pack voltage 288 V
Number of NiMH battery modules in the pack 30
NiMH battery module voltage 9.6 V
NiMH battery module dimensions 1 x 15 x 3.3 in
(18.5 x 382 x 86 mm)
NiMH module weight 3.3 lbs (1.5 kg)
NiMH battery pack dimensions 25 x 43 x 7 in
(630 x 1080 x 180 mm)
NiMH battery pack weight 152.1 lbs
(69 kg)
Components Powered by the HV Battery Pack
• Front Electric Motor • Rear Electric Motor
• Inverter/Converter • Power Cables
• A/C Compressor • Electric Generator
11

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)
HV Battery Pack Recycling
• The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV
battery Caution Label (see page 36) or the nearest Toyota dealer.
Auxiliary Battery
• The Highlander hybrid also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery
powers the vehicle electrical system similar to a conventional vehicle. As with other conventional
vehicles, the auxiliary battery is grounded to the metal chassis of the vehicle.
• The auxiliary battery is located in the engine compartment.
288 Volt HV Battery Pack HV Battery Pack Mounted in CabinArea
12 Volt Auxiliary Battery in Engine Compartment 12 Volt Auxiliary Battery in Cabin Area
2011 Model
2008
–
2010 Models
12

High Voltage Safety
The HV battery pack powers the high voltage electrical system with DC electricity. Positive and
negative orange colored 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/converter creates 3-phase AC to power the motors.
Power cables are routed from the inverter/converter to each high voltage motor (front and rear electric
motors, electric generator, and A/C compressor). The following systems are intended to help keep
occupants in the vehicle and emergency responders safe from high voltage electricity:
High Voltage Safety System
• A high voltage fuse n* provides short circuit protection in the HV battery pack.
• Positive and negative high voltage power cables o* connected to the HV battery pack are controlled
by 12 Volt normally open relays p*. When the vehicle is shut off, the relays stop electricity flow
from leaving the HV battery pack.
WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or high voltage component.
• Both positive and negative power cables o* are insulated from the metal chassis, so there is no
possibility of electric shock when 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 hybrid vehicle computer q* 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.
*Numbers apply to the illustration on the following page.
13

High Voltage Safety (Continued)
Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 15).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
2008 – 2010 Models
12 Volt Auxiliary
Battery
2011 Model
q
V
olt DC
00
12 Volt Auxiliary
Battery Hybrid Vehicle Computer
o
A
/C
Compressor
o
n
p
HV Battery Pack
Electric
Motor
(Rear)
Electric
Generator p
00
Inverter/
Converter
V
olt DC
Electric
Motor
A
C
3-Phas
2011 Model
2008
–
2010 Models
12 Volt Auxiliary
Battery
12 Volt Auxiliary
Battery
V
olt DC
288
Inverter/
Converter
V
olt DC
288
Hybrid Vehicle Computer
A
/C
Compressor
Electric
Generator
Electric
Motor
(Rear)
Electric
Motor
HV Battery Pack
A
C
3-Phas
14

Precaution to be observed when dismantling the vehicle
WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or high voltage component.
Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating.
• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
• An electrical tester that is capable of measuring DC 750 Volts or more.
15

16
Spills
The Highlander hybrid contains the same common automotive fluids used in other non-hybrid Toyota
vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery
electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however,
is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked.
A catastrophic crash that would breach both the metal battery pack case and a metal battery module
would be a rare occurrence.
A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral) substance
is approximately in the middle of this scale. Adding a weak acidic mixture, such as a dilute boric acid
solution or vinegar, to the caustic alkaline electrolyte will cause the electrolyte to be neutralized. This
is similar but opposite to the use of baking soda to neutralize a lead-acid battery electrolyte spill.
A Toyota Material Safety Data Sheets (MSDS) is attached to this document.
• Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. A fold down face shield is not acceptable for acid or
electrolyte spills.
• Rubber, latex or nitrile gloves.
• Apron suitable for alkaline.
• Rubber boots.
• Neutralize NiMH electrolyte.
• Use a boric acid solution or vinegar.
• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to 1
gallon of water.