Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM1000000026Q3I
Model Year Start: 2023 Model: RAV4 HV Prod Date Range: [10/2022 - 10/2023]
Title: HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL; 2023 MY RAV4 HV [10/2022 - 10/2023]

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 junction block assembly 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 2023 MY RAV4 HV [10/2022 - 10/2023]; 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

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system*

Pre-collision system

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

Back door lock initialization

Power door lock control system

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

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 2019 - 2024 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): PRECAUTION

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

NOTICE:

  • After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
  • When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition 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.

2. REMOVE SERVICE PLUG GRIP

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

3. DISCONNECT ENGINE ROOM MAIN WIRE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL+

4. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

5. CHECK TERMINAL VOLTAGE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

6. INSTALL CONNECTOR COVER ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

7. CONNECT ENGINE ROOM MAIN WIRE

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

8. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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

9. REMOVE REAR SEAT CUSHION LOCK HOOK

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

10. 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 Rear Floor): REMOVAL+

11. REMOVE REAR DOOR SCUFF PLATE LH

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

12. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

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

13. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

14. REMOVE NO. 2 BATTERY SERVICE COVER BOARD

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

15. REMOVE BATTERY SERVICE COVER BOARD

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

16. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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

17. REMOVE NO. 1 HV BATTERY COVER PANEL RH

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

18. DISCONNECT FLOOR UNDER WIRE

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

19. 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.

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

20. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

21. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

Click here 2023 MY RAV4 HV [10/2022 - 10/2023]; HYBRID / BATTERY CONTROL: BATTERY VOLTAGE SENSOR: REMOVAL+

22. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the bolt and disconnect the electric vehicle battery plug assembly.

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

NOTICE:

Insulate the disconnected connectors with insulating tape.

(c) Disengage the clamp.

(d) Disengage the 2 claws and open the wiring harness protector.

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

NOTICE:

Insulate the disconnected connectors with insulating tape.

(f) Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the wiring harness protector.

*a

Protective Tape

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

(h) Remove the 4 nuts and HV battery junction block assembly from the HV battery.

NOTICE:

If the HV battery junction block assembly has been struck or dropped, replace it with a new one.