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

Click here 2019 - 2024 MY RAV4 HV [02/2019 -        ]; A25A-FXS (FUEL): FUEL TANK (w/ Canister Pump Module): INSTALLATION

3. INSTALL EXHAUST MANIFOLD

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: INSTALLATION

4. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST PIPE: INSTALLATION+

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

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

13. INSTALL FRONT FLOOR COVER LH

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

14. INSTALL ENGINE UNDER COVER HEAT INSULATOR

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

15. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

16. INSTALL NO. 1 ENGINE UNDER COVER

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

17. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

18. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION+

19. INSTALL FRONT WHEELS

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; MAINTENANCE: TIRE AND WHEEL: INSTALLATION

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

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): INSTALLATION+

22. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: INSTALLATION+

23. INSTALL BATTERY SERVICE COVER BOARD

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: INSTALLATION+

24. INSTALL NO. 2 BATTERY SERVICE COVER BOARD

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: INSTALLATION+

25. INSTALL REAR DOOR SCUFF PLATE LH

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: INSTALLATION+

26. INSTALL NO. 3 BATTERY SERVICE COVER BOARD

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: INSTALLATION+

27. INSTALL REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

Click here 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: INSTALLATION+

28. INSTALL REAR SEAT CUSHION LOCK HOOK

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; SEAT: REAR SEAT ASSEMBLY: INSTALLATION+

29. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; SEAT: REAR SEAT ASSEMBLY: INSTALLATION+

30. CONNECT FLOOR UNDER WIRE

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): INSTALLATION+

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

Click here 2019 - 2024 MY RAV4 HV [11/2018 -        ]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: INSTALLATION

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

Click here 2020 - 2021 MY RAV4 HV [06/2020 - 12/2021]; REAR SUSPENSION: REAR SUSPENSION MEMBER (for HV Model AWD): INSTALLATION+ 2022 - 2024 MY RAV4 HV [12/2021 -        ]; REAR SUSPENSION: REAR SUSPENSION MEMBER (for HV Model AWD): INSTALLATION+