Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000002FR6S
Model Year Start: 2024 Model: RAV4 HV Prod Date Range: [10/2023 -           ]
Title: HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL; 2024 MY RAV4 HV [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 inverter with converter 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 2024 MY RAV4 HV [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

2024 MY RAV4 RAV4 HV [10/2023 -        ]; DOOR / HATCH: POWER BACK DOOR SYSTEM: 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

Replacement of inverter with converter assembly

Resolver learning
  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

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

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

Replacement of ECM

Perform Vehicle Identification Number (VIN) registration

DTC P063051 is output

2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: REGISTRATION

Grill shutter switch specification infomation

Vehicle control history (RoB) [X260E] is stored

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; A25A-FXS (ENGINE CONTROL): SFI 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.
    • for NICKEL METAL HYDRIDE BATTERY:

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

    • for LITHIUM-ION BATTERY:

      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 the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) auxiliary battery terminal.

Waiting Time before Disconnecting Cable from Negative (-) Auxiliary Battery Terminal

System Name

See Procedure

Vehicle enrolled in Toyota Audio Multimedia system or safety connect system

6 minutes

Vehicle not enrolled in Toyota Audio Multimedia system and safety connect system

1 minute

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 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

3. DRAIN COOLANT (for Inverter)

Click here 2022 - 2024 MY RAV4 HV [12/2021 -        ]; HYBRID / BATTERY CONTROL: COOLANT (for Inverter): REPLACEMENT+

4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here 2024 MY RAV4 HV [10/2023 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

5. REMOVE INLET AIR CLEANER ASSEMBLY

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

6. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

7. REMOVE ECM

Click here 2024 MY RAV4 HV [10/2023 -        ]; A25A-FXS (ENGINE CONTROL): ECM: REMOVAL+

8. DISCONNECT 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) Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.

NOTICE:

  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • Insulate the disconnected terminals with insulating tape.
  • Do not touch the waterproof seal or terminals of the connector.

(b) Remove the bolt.

(c) Disengage the clamp and disconnect the engine room main wire.

9. REMOVE CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt (B).

*a

Bolt (A)

*b

Bolt (B)

(b) 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.

10. CHECK TERMINAL VOLTAGE

CAUTION:

Be sure to wear insulated gloves.

(a) 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.

11. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Temporarily install the connector cover assembly to the inverter with converter assembly.

(b) Using a T25 "TORX" socket wrench, install the bolt.

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

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.

12. DISCONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts and disconnect the HV floor under wire from the inverter with converter assembly.

NOTICE:

  • Do not damage the terminals, interlock connector or inverter with converter assembly during disconnection.
  • Do not touch the waterproof seal or terminals of the connector.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Although the connector may feel loose, this is not due to a malfunction.

*a

Waterproof Seal

(b) Remove the 2 nuts and disconnect the HV floor under wire from the inverter with converter assembly.

(c) Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.

NOTICE:

  • Do not touch the waterproof seal or terminals of the connector.
  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Insulate the disconnected terminals with insulating tape.

*a

Waterproof Seal

13. DISCONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts.

*a

Waterproof Seal

(b) Disengage the clamp and disconnect the HV air conditioning wire from the inverter with converter assembly.

NOTICE:

  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Do not touch the waterproof seal or terminals of the connector.
  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Insulate the disconnected terminals with insulating tape.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

14. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the nut and wire harness clamp bracket.

15. DISCONNECT ENGINE 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) Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.

NOTICE:

  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • Insulate the disconnected terminals with insulating tape.
  • Do not touch the waterproof seal or terminals of the connector.

(b) Disengage the clamp (A) and disconnect the No. 1 fuel vapor feed hose.

(c) Remove the bolt.

(d) Disengage the 3 clamps (B).

(e) Disengage the 2 clamps (A) and disconnect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

(f) Remove the bolt.

(g) Disengage the clamp (B).

(h) Disconnect the EGR valve connector.

(i) Disconnect the generator temperature sensor connector, resolver (transmission fluid temperature sensor) connector and shift lever position sensor connector and disengage the clamp.

*a

Generator Temperature Sensor Connector

*b

Resolver (Transmission Fluid Temperature Sensor) Connector

*c

Shift Lever Position Sensor Connector

NOTICE:

After disconnecting the engine wire, cover the connector of the generator temperature sensor, resolver (transmission fluid temperature sensor) and shift lever position sensor with tape (non-residue type) or equivalent to prevent the entry of foreign matter or water.

(j) Disengage the 2 clamps.

(k) Remove the bolt.

(l) Remove the bolt.

(m) Disengage the 2 claws and open the engine wire terminal cover.

(n) Remove the nut.

(o) Disengage the 2 clamps and disconnect the engine wire from the inverter with converter assembly.

16. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

(b) Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with the clip from the No. 1 transmission control cable bracket.

(c) Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.

(d) Remove the 2 bolts and disconnect the transmission control cable assembly from the inverter with converter assembly.

17. DISCONNECT NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.

NOTICE:

Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

18. DISCONNECT NO. 4 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the No. 4 inverter cooling hose from the inverter with converter assembly.

NOTICE:

Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

19. REMOVE INVERTER COVER

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts and inverter cover from the inverter with converter assembly.

NOTICE:

  • Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.
  • Do not touch the waterproof seal of the inverter cover.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • When removing the inverter cover, do not pull the areas (A) as they may deform.
  • Make sure that the interlock is installed to the inverter cover.
  • Do not remove or excessively tighten the screw of the inverter cover.

    *1

    Inverter Cover

    *a

    Do not remove or excessively tighten the screw
  • Although the inverter cover may feel loose, this is not due to a malfunction.

HINT:

If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.

*a

Interlock

*b

Waterproof Seal

20. DISCONNECT MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Adhere to the following removal procedure. Otherwise, the connector and the inverter with converter assembly may be damaged.

(a) Using an insulated tool, remove the 6 bolts.

NOTICE:

  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Do not touch the waterproof seal or terminals of the motor cable.

(b) Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.

*a

Waterproof Seal

NOTICE:

  • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  • Do not touch the waterproof seal or terminals of the motor cable.
  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Insulate the disconnected terminals with insulating tape.
  • After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

21. REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 5 bolts, 2 nuts and inverter with converter assembly.

NOTICE:

  • When removing the inverter with converter assembly, be careful not to damage the parts around it.
  • To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.
  • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

HINT:

Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly so that coolant does not spill out.

22. REMOVE NO. 1 INVERTER BRACKET

NOTICE:

Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

*a

Bottom of Inverter with Converter Assembly

*b

Support

(a) Set the inverter with converter assembly on wooden blocks.

*a

Wooden Block

(b) Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.

23. REMOVE NO. 2 INVERTER BRACKET

(a) Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.

*a

Wooden Block

24. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.

(b) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

(c) Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.

(d) Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.

(e) Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.