22TE09-1

TECHNICAL INSTRUCTIONS
FOR
CUSTOMER SUPPORT PROGRAM 22TE09
HV FLOOR UNDER WIRE HARNESS AND REAR TRACTION MOTOR CABLE
CORROSION
CERTAIN 2020 –2022 MODEL YEAR HIGHLANDER HYBRID AWD
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this repair
are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service
Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this repair
are required to currently hold at least one of the following certification levels:
•
•
•
Hybrid Expert Technician
Master Technician
Master Diagnostic Technician
Always check which technicians can perform the recall remedy by logging on to https://www.uotdealerreports.com. It
is the dealership’s responsibility to select technicians with the above certification level or greater to perform this repair.
Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is
important to consider technician days off and vacation schedules to ensure there are properly trained technicians
available to perform this repair at all times.
I.
OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches R.O.
2. Check vehicle is covered under CSP
Not Covered
No further action required.
Covered
Inspect the vehicle for DTC and or AM
static
Vehicle not affected
Condition confirmed
Does the Rear Traction Motor Cable have
corrosion on the chamfer per inspection
Yes
No
Replace HV Floor Under Wire
Replace both HV Floor Under Wire
Harness and Rear Traction Motor Cable
Repair Complete
II. BACKGROUND
Although the HV Floor Under Wire Harness and Rear Traction Motor Cable is covered by Toyota’s New Vehicle
Limited Warranty for 3 years or 36,000 miles (whichever comes first), we at Toyota care about the customers’
ownership experience. Toyota is providing coverage for repairs related to excessive corrosion to the wire harness
connections at the Rear Motor Generator. Excessive corrosion can cause AM Radio Static during certain drive
cycles, or the vehicle may not start.
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III. IDENTIFICATION OF AFFECTED VEHICLES
•
•
Check TIS to confirm the VIN is involved in this Customer Support Program
TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected.
IV. PREPARATION
A. PARTS
Dealers are not to order parts for stock.
HV Floor Under Wire Harness Repair Parts
NAP Production
Part Number
Description
HV
Floor
Under Wire Harness
821H1-0E051
Rear Seat Cushion Hook Clips
72693-48010
Gasket, Exhaust Pipe
90917-A6002
Gasket, Exhaust Pipe
17451-F0020
Nut, Lock
90177-A0021
Bolt, Flange
90105-A0369
Qty
1
2
1
1
2
2
Rear Traction Motor Cable Parts: Only requires replacement based on inspection standard.
NAP Production
Part Number
Description
Qty
G1149-42010
G114D-47021
90105-A0420
90119-A0512
Rear Traction Motor Cable
Cap Motor Cable Terminal
Bolt, w Washer
Bolt, W Washer
1
1
2
1
B. TOOLS & EQUIPMENT
•
•
Techstream
Basic Hand Tools
•
•
Transmission Jack
Torque wrench
•
•
Screw Jack
DVOM
SST- The following tools are essential service tools that all dealers are required to have.
Part Number
01413-00072 (Small)
01413-00073 (Medium)
01413-00074 (Large)
Part Description
Insulated Tools
Quantity
As needed
Insulated Glove Set, Rubber with Leather
Protectors*
1
CAUTION
ALWAYS inspect the insulated gloves before use for cracks, ruptures, tears, pinholes, or damage. Do
NOT wear if damaged.
V. CONFIRM CONDITION EXISTS AND CABLE INSPECTION
1) Perform a heath check and confirm if DTC P0AA649 OR P1C8049 are present
YES – Continue to Step 3
NO – Continue to Step 2
For part release a screen shot is required of DTC from Techstream and the VIN must be in screen shot.
2) Inspect the vehicle for AM static radio interference
a) Ready on vehicle
b) Change the radio to a known AM station
c) After radio is on a known station, place the vehicle into drive or reverse while applying the brake
d) Return the vehicle to Park after 3 seconds
e) Repeat c and d 3 times
When placing vehicle into drive or reverse is am static introduced each time placed into Drive or
Reverse?
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YES – Continue to Step 3
NO- This CSP does not apply. Please consult the repair manual and continue diagnosis.
3) Disable High Voltage Circuit for Inspection
a) Temporarily disconnect 12 v battery
b) Remove hybrid service plug
c) Remove bolt (B) at inverter as shown.
d) Using a T25 "TORX" socket wrench, remove the bolt (A)
and connector cover assembly from the inverter with
converter assembly.
NOTICE:
• Do not touch the connector cover assembly waterproof seal.
• Do not allow any foreign matter or water to enter the inverter
with converter assembly.
e) Using a voltmeter, measure the voltage between the
terminals of the 2 phase connectors.
Standard Voltage: 0 V
NOTICE: Do not allow any foreign matter or water to enter the
inverter with converter assembly.
HINT: Use a measuring range of DC 750 V or more on the
voltmeter.
CAUTION
Be sure to wear insulated gloves.
Y6 connector under vehicle at MGR
4) Inspect the Y6 connection for corrosion.
f) Disconnect the Y6 connector at the MGR and inspect for
corrosion, dirt, or debris.
CAUTION
Orange wire harnesses and connectors indicate high-voltage
circuits. To prevent electric shock, always follow the procedure
described in the repair manual to disable
the high-voltage system.
To prevent electric shock, wear insulated gloves when working on
wire harnesses and components of the high-voltage system.
YES –Continue to Section VI
For parts release take photo of connector housing with R.O in
picture.
NO - This CSP does not apply. Please consult the repair
manual and continue diagnosis.
5) Inspect the connector housing of the MGR.
a) Inspect the chamfer of the MGR connector housing for pitting and corrosion on the sealing surface.
Corrosion in this area will cause the seal to leak. Is pitting and corrosion present?
YES – Rear Traction Motor Cable requires replacement, continue to Section VI
Take photo of connector housing with R.O in picture for parts release.
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NO – Rear Traction Motor Cable does NOT require replacement, continue to Section VI
NG
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VI. CABLE REMOVAL PROCEDURE
A. HV FLOOR UNDER WIRE REMOVAL
1. Remove the HV Floor Under Wire following the repair manual procedure.
Refer to TIS, applicable model and model year Repair Manual:
• 2020 / 2021 / 2022 Highlander HV:
“Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Frame Wire: Removal”
B. REAR TRACTION MOTOR CABLE REMOVAL (if required based on inspection in Section V, if not
required skip to Section VII.B)
1. Disconnect MGR Ground Plug/Sensor (if vehicle is equipped)
a) Remove the bolt from the ground and bracket.
2. Place transmission jack under MGR and secure.
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3. Remove MGR mounting bolts
a) Remove MGR rear mount bolt
b) Remove the front mount inner bolts (Do not remove outer bolts)
c) Slowly tilt the MGR assembly 3 inches to gain clearance with
the body. (Do not remove assembly)
CAUTION
Do not lower too far to avoid damage to drive shafts.
4. Remove the Rear Traction Motor Cable side mount bolts.
V
5. Remove Motor Cable Terminal Cap (Non-Reusable)
a) Slide the cover on the top side of the rear traction motor cable.
b) Clean area with shop air and rag around the cover to avoid debris
falling in.
NOTICE:
• Some vehicles may be extremely dirty in this area, ensure
you clean thoroughly before removing cover.
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c) Disengage the 2 claws to remove the motor cable terminal cap
from the rear traction motor with transaxle assembly.
6. Rear Traction Motor Cable
a) Remove Rear Traction Motor Cable High Voltage Mount Bolts
b) Remove Rear Traction Motor Cable from MGR Assembly.
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VII. CABLE INSTALL PROCEDURE
A. REAR TRACTION MOTOR CABLE INSTALLATION (if required based on inspection in Section V, if not
required skip to Section VII. B)
1. Install the Rear Traction Motor Cable onto the MGR
a) Clean the area around the terminal of the rear traction motor
cable, and then blow air on the terminal to remove dust and
other foreign matter.
NOTICE:
• Blowing air without cleaning first may cause dust and other
foreign matter to enter the terminal.
• Dust or other foreign matter entering the terminal when
installing the rear traction motor cable may cause a short
or electrical leakage.
b) Using an insulated tool, install the rear traction motor cable to
the rear traction motor with transaxle assembly with the 3 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
Torque is critical at this electrical connection. Ensure
this is torqued properly for each bolt.
2. Install the new motor cable terminal cap.
a) Engage the 2 claws to install a new motor cable terminal cap to
the rear traction motor with transaxle assembly.
NOTICE:
• Do not pinch the O-ring.
• Check that the motor cable terminal cap is securely
installed
b) Slide the cover on the top side of the rear traction motor cable.
3. Install the 4 bolts for the rear traction motor cable.
Torque:
22 N·m {224 kgf·cm, 16 ft·lbf}
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4. Raise the MGR with Transmission Jack
5. Reinstall the MGR mounting bolts.
a) Temporarily install bolts A and B
b) Torque bolts to spec starting with A and then moving to B
A
A
Torque:
for bolts A :
55 N·m {561 kgf·cm, 41 ft·lbf}
for bolt B :
130 N·m {1326 kgf·cm, 96 ft·lbf}
B
c) After tightening bolt b, make sure the inner cylinder mark and
rubber part mark are positioned as shown.
6. Reinstall MGR Ground Plug/Sensor
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a) Reinstall ground wire to bracket with bolt and torque to spec.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
B. INSTALL THE HV FLOOR UNDER WIRE.
1. Install the HV Floor Under Wire following the repair manual procedure.
Refer to TIS, applicable model and model year Repair Manual:
• 2020 / 2021 / 2022 Highlander HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Frame Wire: Installation”
NOTICE: When installing the new HV Floor Under Harness ensure to leave the cover on the wire harness for
the inverter connector to protect it during the installation and routing.
2. Using Techstream, run a Health Check to verify DTCs P0AA649 and/or P1C8049 are no longer present
and/or repeat inspection steps in section V-2 to confirm AM static is no longer present.
3. Test-drive the vehicle to ensure the condition no longer exists and the vehicle exhibits proper operation.
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−
−
−
◄ VERIFY REPAIR QUALITY ►
Confirm the high voltage bolts are properly torqued to spec.
Confirm the MGR bolts are torqued to spec and rear mount is properly aligned
Confirm the cables are properly routed and secured.
Confirm related DTCs P0AA649, P1C8049 and/or AM static are no longer present
If you have any questions regarding this update, please contact your regional representative.
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