Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000002FR7A
Model Year Start: 2024 Model: RAV4 HV Prod Date Range: [10/2023 -           ]
Title: HYBRID / BATTERY CONTROL: FRAME WIRE: 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 floor under wire 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 air fuel ratio sensor
  • Gas leak from exhaust system is repaired

Inspection After Repair

  • Poor idle, etc.
  • Engine start function, etc.

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 AWD with 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 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.
  • 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.

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 NO. 1 FLOOR UNDER COVER (w/ NO. 1 FLOOR UNDER COVER)

Click here 2024 MY RAV4 HV [10/2023 -        ]; REAR SUSPENSION: REAR SUSPENSION MEMBER (for HV Model AWD): REMOVAL+

3. REMOVE SERVICE PLUG GRIP

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

4. 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.

5. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

6. CHECK TERMINAL VOLTAGE

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

7. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

8. DISCONNECT FLOOR UNDER WIRE

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

9. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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

10. REMOVE REAR SEAT CUSHION LOCK HOOK

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; SEAT: REAR SEAT ASSEMBLY: 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 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

18. 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.

(c) Disengage the 3 claws to remove the No. 4 relay block cover.

(d) Remove the nut.

(e) Disengage the clamp.

(f) Disengage the clamp and disconnect HV floor under wire.

19. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH

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

20. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH

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

21. REMOVE NO. 1 ENGINE UNDER COVER

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

22. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

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

23. REMOVE ENGINE UNDER COVER HEAT INSULATOR

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

24. REMOVE FRONT FLOOR COVER LH

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

25. REMOVE FRONT FLOOR COVER RH

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

26. REMOVE FRONT CENTER FLOOR COVER

(a) Remove the 2 clips and front center floor cover.

27. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR

(a) Remove the 2 nuts, clip and front No. 2 floor heat insulator.

28. REMOVE FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

(a) Remove the nut, bolt, clip and front lower No. 1 floor heat insulator.

29. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

(a) Remove the 2 nuts and front No. 1 floor heat insulator.

30. REMOVE NO. 2 ENGINE SERVICE COVER CUSHION

(a) Remove the 2 nuts and No. 2 engine service cover cushion.

31. REMOVE ENGINE SERVICE COVER CUSHION

(a) Remove the 2 nuts and engine service cover cushion.

32. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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

33. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL+

34. REMOVE EXHAUST MANIFOLD

Click here 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

35. REMOVE FUEL TANK ASSEMBLY

Click here 2024 MY RAV4 HV [10/2023 -        ]; A25A-FXS (FUEL): FUEL TANK (w/ Canister Pump Module): REMOVAL

36. REMOVE FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Insulate the disconnected connectors with insulating tape.

(a) Remove the 2 nuts snd 2 bolts.

Bolt

Nut

(b) Disengage the grommet and pull out the HV floor under wire from the floor panel hole.

(c) Remove the 3 bolts and nut.

(d) Remove the 2 stud clamps.

NOTICE:

If the stud clamps are removed forcibly, the stud bolts may be damaged.

(e) Remove the 2 nuts, bolt and 2 stud clamps.

NOTICE:

If the stud clamps is removed forcibly, the stud bolt may be damaged.

(f) Disengage the 2 claws.

Remove in this Direction

(g) Disengage the guide and disconnect the No. 1 terminal cap.

(h) Remove the nut and disconnect the engine room main wire.

(i) Remove the 2 nuts and HV floor under wire.

(j) Disengage the clamp.

(k) Remove the 2 bolts and HV floor under wire from the rear traction motor with transaxle assembly.

NOTICE:

  • Do not damage the terminals, interlock connector or rear traction motor with transaxle 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 rear traction motor with transaxle assembly.
  • Although the connector may feel loose, this is not due to a malfunction.

*a

Waterproof Seal