Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000002FR7H
Model Year Start: 2024 Model: RAV4 HV Prod Date Range: [10/2023 -           ]
Title: HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (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 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 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

Power back door initialization

Power door lock control system

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

Replacement of HV battery junction block assembly

Current sensor offset learning

DTCs are stored

2020 - 2024 MY RAV4 HV [06/2020 -        ]; HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): INSTALLATION+

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 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.
  • 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. REMOVE SERVICE PLUG GRIP

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

2. DISCONNECT ENGINE ROOM MAIN WIRE

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL+

3. REMOVE CONNECTOR COVER ASSEMBLY

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

4. CHECK TERMINAL VOLTAGE

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

5. INSTALL CONNECTOR COVER ASSEMBLY

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): REMOVAL+

6. CONNECT ENGINE ROOM MAIN WIRE

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

7. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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

8. REMOVE REAR SEAT CUSHION LOCK HOOK

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

9. REMOVE REAR DOOR SCUFF PLATE LH

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

10. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

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

11. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

12. REMOVE NO. 2 BATTERY SERVICE COVER BOARD

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

13. REMOVE BATTERY SERVICE COVER BOARD

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

14. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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

15. REMOVE NO. 1 HV BATTERY COVER PANEL RH

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): REMOVAL+

16. 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.

17. DISCONNECT FLOOR WIRE

Click here 2024 MY RAV4 HV [10/2023 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): REMOVAL+

18. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

*A

for Type A

*B

for Type B

(1) for Type A:

Disengage the 2 claws and open the wiring harness protector.

(2) for Type B:

Disengage the claw and open the wiring harness protector.

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

NOTICE:

Insulate the disconnected high-voltage connector with insulating tape.

(c) Disconnect the hybrid battery terminal block connector.

NOTICE:

Insulate the disconnected high-voltage connector with insulating tape.

(d) Remove the bolt and electric vehicle battery plug assembly from the HV battery.

(e) Disconnect the 2 HV battery junction block assembly connectors.

NOTICE:

Insulate the disconnected high-voltage connectors with insulating tape.

*A

for Type A

*B

for Type B

*a

Protective Tape

-

-

(1) for Type A:

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

(2) for Type B:

Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the wiring harness protector.

(g) 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.