Last Modified: 05-08-2025 6.11:8.1.0 Doc ID: RM100000002FR6X
Model Year Start: 2024 Model: RAV4 HV Prod Date Range: [10/2023 -           ]
Title: HYBRID / BATTERY CONTROL: BATTERY VOLTAGE SENSOR: REMOVAL; 2024 - 2025 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 battery voltage sensor removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedures

Effect/Inoperative Function when Necessary Procedures not Performed

Link
*: When performing learning using the Techstream.

Click here 2024 - 2025 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 - 2025 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: UTILITY

Parking support brake system*

Pre-collision system

Reset back door close position

power back door system

2024 - 2025 MY RAV4 RAV4 HV [10/2023 -        ]; DOOR / HATCH: POWER BACK DOOR SYSTEM: INITIALIZATION

Back door lock initialization

power door lock control system

2019 - 2025 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Replacement of HV battery

Battery status info update

HV battery status information cannot be updated

2019 - 2025 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE BATTERY): UTILITY

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 - 2025 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:

  • The type of battery voltage sensor to be used varies depending on the vehicle model.
  • The type of battery voltage sensor can be confirmed by the color of the label.

    *a

    Blue Label
  • If the wrong type of battery voltage sensor is installed, the ignition switch cannot be turned on (READY).
  • After installing the battery voltage sensor, perform the following to check that the ignition switch can be turned on (READY).
    • Turn the ignition switch on (READY).
    • Turn the ignition switch off and wait for 30 seconds or more.
    • Turn the ignition switch on (READY) again.
  • 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 HV BATTERY

Click here 2024 - 2025 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL

3. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the 8 bolts, 4 nuts and upper HV battery cover sub-assembly from the HV battery.

*a

Bolt

*b

Nut

4. REMOVE NO. 1 HV BATTERY SHIELD PANEL

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Disengage the clamp.

(b) Disconnect the battery voltage sensor connector.

(c) Remove the bolt and nut.

(d) Remove the No. 1 HV battery shield from the HV battery.

Remove in this Direction

5. REMOVE BATTERY VOLTAGE SENSOR

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Disconnect the battery voltage sensor connector.

NOTICE:

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

(b) Remove the bolt and battery voltage sensor from the HV battery.

NOTICE:

If the battery voltage sensor has been struck or dropped, replace it.