Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001WM5P
Model Year Start: 2021 Model: RAV4 HV Prod Date Range: [08/2020 - 12/2021]
Title: HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): REMOVAL; 2021 MY RAV4 HV [08/2020 - 12/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV battery removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedure not Performed

Link
*: When performing learning using the Techstream.

Click here 2019 - 2022 MY RAV4 HV [02/2019 - 10/2022]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system*

Pre-collision system

Lighting system (EXT) (w/ AFS)

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Reset back door close position

Power back door system

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): INITIALIZATION

Power back door initialization

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Replacement of HV battery
  1. Battery status info update
  2. Prediagnostic battery charge
  3. Battery diagnosis

HV battery status information cannot be updated

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY

Replacement of hybrid battery terminal block

High voltage fuse accumulated load history reset

DTCs are stored

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY

  • Replacement of battery ECU assembly
  • Replacement of HV battery junction block assembly

Current sensor offset learning

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): INSTALLATION+

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:

  • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

  • When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.

    Click here 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION

  • If the HV battery has been struck or dropped, replace it.
  • When connecting a connector to the HV battery, confirm that the connector is securely connected through the following:

    - Push the connector until a click sound is heard.

    - Visually check and confirm that the connector is securely connected by pulling on it.

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

  • When performing repairs around the HV battery, such as using a tap, do not allow metal shavings to enter the HV battery.
  • Do not touch any high voltage wire harnesses, connectors or parts with bare hands.
  • Hold the areas shown in the illustration and lift the HV battery.
  • Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.
  • Do not put your hands into the openings of the HV battery.

    *a

    Opening
  • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
  • Do not climb on top of or stand on the HV battery.
  • Do not allow any foreign matter or water to enter the HV battery.
  • If any bolts, nuts or clips are dropped into the HV battery, make sure to remove them.

HINT:

When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

PROCEDURE

1. READ VALUE USING TECHSTREAM

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid/EV Battery Temperature 1 to 6.

Powertrain > Hybrid Control > Data List

Tester Display

Hybrid/EV Battery Temperature 1

Hybrid/EV Battery Temperature 2

Hybrid/EV Battery Temperature 3

Hybrid/EV Battery Temperature 4

Hybrid/EV Battery Temperature 5

Hybrid/EV Battery Temperature 6

(d) Read the Data List.

NOTICE:

If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

2. REMOVE SERVICE PLUG GRIP

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

3. DISCONNECT ENGINE ROOM MAIN WIRE

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL+

4. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

5. CHECK TERMINAL VOLTAGE

Click here 2021 MY RAV4 HV [08/2020 - 12/2021]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

6. INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

NOTICE:

Do not touch the waterproof seal of the connector cover assembly.

*a

Bolt (A)

*b

Bolt (B)

(b) Install the bolt (B).

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

7. CONNECT ENGINE ROOM MAIN WIRE

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

8. REMOVE BATTERY COOLING BLOWER ASSEMBLY

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

9. REMOVE NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Be sure to wear insulated gloves.

(a) Using the service plug grip, remove the battery cover lock striker.

HINT:

Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.

*1

Service Plug Grip

*2

Battery Cover Lock Striker

*a

Projection

*b

Turn

*c

Button

(b) Remove the 3 bolts, 3 nuts and No. 1 HV battery cover panel RH from the HV battery.

10. DISCONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disconnect the 2 HV battery junction block assembly connectors.

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

*a

Shield Ground

(b) Disconnect the shield ground from the HV battery.

11. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

*a

Electric Vehicle Battery Plug Assembly Connector

*b

HV Battery Junction Block Assembly Connector

(b) Disconnect the electric vehicle battery plug assembly connector.

(c) Disconnect the HV battery junction block assembly connector.

12. REMOVE HYBRID BATTERY HOSE ASSEMBLY

(a) Disconnect the hybrid battery hose assembly from the vehicle body.

(b) Disengage the 2 claws to remove the hybrid battery hose assembly from the HV battery.

13. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; THEFT DETERRENT / KEYLESS ENTRY: ELECTRICAL KEY OSCILLATOR (for Luggage Compartment): REMOVAL+

14. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the 2 clamps to disconnect the floor wire.

15. REMOVE NO. 4 HV BATTERY PROTECTOR

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp to remove the No. 4 HV battery protector from the HV battery.

16. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disconnect the HV battery connector.

17. REMOVE HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 4 bolts.

NOTICE:

  • Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.
  • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
  • Use cardboard or another similar material to protect the HV battery and vehicle body from damage.
  • Since the HV battery is very heavy, 2 people are needed to remove it. When removing the HV battery, be careful not to damage the parts around it.
  • When removing the HV battery from the vehicle, do not allow it to contact the vehicle.
  • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
  • Insulate the disconnected terminals or connectors with insulating tape.
  • If the HV battery has been struck or dropped, replace it.

(b) Disengage the 2 guide pins to remove the HV battery from the vehicle body.

18. REMOVE HOLE PLUG

HINT:

This procedure is only performed when the hole plug is being replaced with a new one.

(a) Remove the hole plug from the vehicle body.

19. PERFORM RECOVERY INSPECTION

(a) Before returning the HV battery, make sure to perform a recovery inspection.

Click here 2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): RECOVERY INSPECTION