HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): REMOVAL; 2024 - 2025 MY RAV4 HV [10/2023

Last Modified: 05-08-2025	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 - 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 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
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system*
		Pre-collision system
	Reset back door close position	Power back door system
	Power back door initialization	Power door lock control system
Replacement of HV battery junction block assembly	Current sensor offset learning	DTCs are stored

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
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

2. DISCONNECT ENGINE ROOM MAIN WIRE

Click here

3. REMOVE CONNECTOR COVER ASSEMBLY

Click here

4. CHECK TERMINAL VOLTAGE

Click here

5. INSTALL CONNECTOR COVER ASSEMBLY

Click here

6. CONNECT ENGINE ROOM MAIN WIRE

Click here

7. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

Click here

8. REMOVE REAR SEAT CUSHION LOCK HOOK

Click here

9. REMOVE REAR DOOR SCUFF PLATE LH

Click here

10. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

Click here

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

13. REMOVE BATTERY SERVICE COVER BOARD

Click here

14. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

Click here

15. REMOVE NO. 1 HV BATTERY COVER PANEL RH

Click here

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

18. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

for Type A

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.

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.