Toyota Highlander Hybrid 6 2005-06

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Remove the service plug grip.
  4.  
  5. Remove the center instrument cluster finish panel.
  6.  
  7. Remove the left and right center floor carpet covers.
  8.  
  9. Remove the front seat center armrest assembly.
  10.  
  11. Remove the console box assembly.
  12.  
  13. Remove power steering converter cover:
    1. Separate wire harness clamps from the power steering converter cover.
    2.  
    3. Remove the 3 nuts and the power steering converter cover.
    4.  

  14.  
  15. Remove the DC-DC converter assembly:
    CAUTION
    Be sure to wear insulated gloves.

    1. Disconnect the 3 connectors from the DC-DC converter assembly.
    2.  
    3. Remove the nut and separate the wire harness clamp.
    4.  
    5. Remove the 2 bolts, nut and the DC-DC converter assembly.
    6.  

  16.  
  17. Remove the ground wire:
    1. Disconnect the ground (earth) wire connector from the DC-DC converter assembly.
    2.  
    3. Remove the nut and the ground wire from the DC-DC converter assembly.

      Click image to see an enlarged view

      Fig. Exploded view of the power steering DC-DC converter and related components

    4.  

  18.  

To install:

  1. Install the ground wire:
    1. Install the ground wire to the DC-DC converter assembly with the nut. Tighten to 49 inch lbs. (5.5 Nm).
    2.  
    3. Connect the ground wire connector to the DC-DC converter assembly.
    4.  

  2.  
  3. Install the DC-DC converter assembly
    CAUTION
    Be sure to wear insulated gloves.

    1. Install the DC-DC converter assembly with the 2 bolts and the nut and tighten to 44 inch lbs. (5 Nm).
    2.  
    3. Attach the 3 connectors to the DC-DC converter assembly.
    4.  
    5. Connect the wire harness clamp to the Dc-DC converter assembly.
    6.  
    7. Install the nut and tighten to 49 inch lbs. (5.5 Nm).
      CAUTION
      Be sure to wear insulated gloves when checking the high voltage cable connector.

    8.  

  4.  
  5. Check that the high voltage cable connector is securely connected to the power steering converter assembly.
  6.  
  7. Install power steering converter cover, as follows:
    1. Install the power steering converter cover with the 3 nuts and tighten to 44 inch lbs. (5 Nm).
    2.  
    3. Install the wire harness clamps to the power steering ECU bracket.
    4.  

  8.  
  9. Install the remaining components in the reverse of the removal procedure.
  10.  
  11. Perform the initialization procedure, as outlined in the Chassis Electrical System.
  12.  

 
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