HYBRID / BATTERY CONTROL: FRAME WIRE: INSTALLATION; 2021 - 2024 MY RAV4 HV [08/2020 - ]

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000001QKYC
Model Year Start: 2021	Model: RAV4 HV	Prod Date Range: [08/2020 - ]
Title: HYBRID / BATTERY CONTROL: FRAME WIRE: INSTALLATION; 2021 - 2024 MY RAV4 HV [08/2020 - ]

INSTALLATION

PROCEDURE

1. INSTALL FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Install the HV floor under wire to the rear traction motor with transaxle assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Make sure that the connector is fully engaged.
Do not damage the terminals, interlock connector or rear traction motor with transaxle assembly during installation.
Do not touch the waterproof seal or terminals of the connector.
Do not allow any foreign matter or water to enter the rear traction motor with transaxle assembly.
Although the connector may feel loose, this is not due to a malfunction.

*a	Waterproof Seal

(b) Engage the clamp.

(c) Insert the HV floor under wire into the floor panel hole and engage the grommet.

(d) Install the 2 nuts and 2 bolts.

	Bolt
	Nut

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Install a new 2 stud clamps.

(f) Install the 3 bolts and nut.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(g) Install a new 2 stud clamps.

(h) Install the bolt and 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(i) Install the 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(j) Connect the engine room main wire to the vehicle body with the nut.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(k) Engage the guide and 2 claws to install the No. 1 terminal cap.

Install in this Direction

2. INSTALL FUEL TANK ASSEMBLY

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3. INSTALL EXHAUST MANIFOLD

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4. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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5. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the vehicle body with the nut.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

6. INSTALL ENGINE SERVICE COVER CUSHION

(a) Install the engine service cover cushion with the 2 nuts.

Torque:

4.9 N·m {50 kgf·cm, 43 in·lbf}

7. INSTALL NO. 2 ENGINE SERVICE COVER CUSHION

(a) Install the No. 2 engine service cover cushion with the 2 nuts.

Torque:

4.9 N·m {50 kgf·cm, 43 in·lbf}

8. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

(a) Install the front No. 1 floor heat insulator with the 2 nuts.

Torque:

4.9 N·m {50 kgf·cm, 43 in·lbf}

9. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

(a) Install the front lower No. 1 floor heat insulator with the nut and bolt.

Torque:

4.9 N·m {50 kgf·cm, 43 in·lbf}

(b) Install the clip.

10. INSTALL FRONT NO. 2 FLOOR HEAT INSULATOR

(a) Install the front No. 2 floor heat insulator with the 2 nuts.

Torque:

4.9 N·m {50 kgf·cm, 43 in·lbf}

(b) Install the clip.

11. INSTALL FRONT CENTER FLOOR COVER

(a) Install the front center floor cover with the 2 clips.

12. INSTALL FRONT FLOOR COVER RH

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13. INSTALL FRONT FLOOR COVER LH

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14. INSTALL ENGINE UNDER COVER HEAT INSULATOR

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15. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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16. INSTALL NO. 1 ENGINE UNDER COVER

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17. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

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18. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

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19. INSTALL FRONT WHEELS

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20. CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the clamp.

(b) Install the HV under floor wire with the nut.

Torque:

7.6 N·m {77 kgf·cm, 67 in·lbf}

(c) Engage the clamp.

(d) Engage the 3 claws to install the No. 4 relay block cover.

(e) Connect the shield ground to the HV battery.

(f) Connect the 2 HV battery junction block assembly connectors.

NOTICE:

Make sure that the connectors are connected securely.

21. INSTALL NO. 1 HV BATTERY COVER PANEL RH

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22. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY

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23. INSTALL BATTERY SERVICE COVER BOARD

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24. INSTALL NO. 2 BATTERY SERVICE COVER BOARD

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25. INSTALL REAR DOOR SCUFF PLATE LH

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26. INSTALL NO. 3 BATTERY SERVICE COVER BOARD

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27. INSTALL REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

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28. INSTALL REAR SEAT CUSHION LOCK HOOK

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29. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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30. CONNECT FLOOR UNDER WIRE

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31. CONNECT ENGINE ROOM MAIN WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Connect the inverter with converter assembly connector and move the lock lever to lock them.

NOTICE:

Do not touch the waterproof seal or terminals of the connectors.
To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.

32. INSTALL SERVICE PLUG GRIP

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33. INSTALL NO. 1 FLOOR UNDER COVER (w/ NO. 1 FLOOR UNDER COVER)

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