- Battery status info update
- Prediagnostic battery charge
- Battery diagnosis
| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000002FR74 |
| Model Year Start: 2024 | Model: RAV4 HV | Prod Date Range: [10/2023 - ] |
| Title: HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): 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 HV battery removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced
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Replaced Part or Performed Procedure |
Necessary Procedures |
Effect/Inoperative Function when Necessary Procedure not Performed |
Link |
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*: When performing learning using the Techstream.
Click here
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Auxiliary battery terminal is disconnected/reconnected |
Perform steering sensor zero point calibration |
Lane control system |
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Parking support brake system* |
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Pre-collision system |
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Reset back door close position |
Power back door system |
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Power back door initialization |
Power door lock control system |
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Replacement of HV battery |
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HV battery status information cannot be updated |
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Replacement of hybrid battery terminal block |
High voltage fuse accumulated load history reset |
DTCs are stored |
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Current sensor offset learning |
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CAUTION:
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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](/t3Portal/stylegraphics/info.gif)
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To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
NOTICE:
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When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.
Click here
- If the HV battery has been struck or dropped, replace it.
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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.
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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.
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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.
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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.
- 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.
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
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Tester Display |
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Hybrid/EV Battery Temperature 1 |
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Hybrid/EV Battery Temperature 2 |
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Hybrid/EV Battery Temperature 3 |
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Hybrid/EV Battery Temperature 4 |
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Hybrid/EV Battery Temperature 5 |
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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
3. DISCONNECT ENGINE ROOM MAIN WIRE
Click here
4. REMOVE CONNECTOR COVER ASSEMBLY
Click here
5. CHECK TERMINAL VOLTAGE
Click here
6. INSTALL CONNECTOR COVER ASSEMBLY
CAUTION:
Be sure to wear insulated gloves.
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(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. |
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(b) Install the bolt (B).
Torque:
8.0 N·m {82 kgf·cm, 71 in·lbf}
7. CONNECT ENGINE ROOM MAIN WIRE
Click here
8. REMOVE BATTERY COOLING BLOWER ASSEMBLY
Click here
9. REMOVE NO. 1 HV BATTERY COVER PANEL RH
CAUTION:
Be sure to wear insulated gloves.
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(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. |
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(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.
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(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. |
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(b) Disconnect the shield ground from the HV battery.
11. DISCONNECT FLOOR WIRE
CAUTION:
Be sure to wear insulated gloves.
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(a) Disengage the clamp. |
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(b) Disconnect the electric vehicle battery plug assembly connector.
(c) Disconnect the HV battery junction block assembly connector.
12. REMOVE HYBRID BATTERY HOSE ASSEMBLY
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(a) Disconnect the hybrid battery hose assembly from the vehicle body. |
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(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
14. DISCONNECT FLOOR WIRE
CAUTION:
Be sure to wear insulated gloves.
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(a) Disengage the 2 clamps to disconnect the floor wire. |
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15. REMOVE NO. 4 HV BATTERY PROTECTOR
CAUTION:
Be sure to wear insulated gloves.
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(a) Disengage the clamp to remove the No. 4 HV battery protector from the HV battery. |
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16. DISCONNECT FLOOR WIRE
CAUTION:
Be sure to wear insulated gloves.
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(a) Disconnect the HV battery connector. |
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17. REMOVE HV BATTERY
CAUTION:
Be sure to wear insulated gloves.
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(a) Remove the 4 bolts. NOTICE:
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(b) Disengage the 2 guide pins to remove the HV battery from the vehicle body. |
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18. REMOVE HOLE PLUG
HINT:
This procedure is only performed when the hole plug is being replaced with a new one.
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(a) Remove the hole plug from the vehicle body. |
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19. PERFORM RECOVERY INSPECTION
(a) Before returning the HV battery, make sure to perform a recovery inspection.
Click here
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