| Last Modified: 05-08-2025 | 6.11:8.1.0 | Doc ID: RM100000002FR8T |
| Model Year Start: 2024 | Model: RAV4 HV | Prod Date Range: [10/2023 - ] |
| Title: HYBRID / BATTERY CONTROL: FUSE BOX (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 hybrid battery terminal block 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 hybrid battery terminal block |
Perform high voltage fuse accumulated load history reset |
DTCs are stored |
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Replacement of HV battery junction block assembly |
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.
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![2020 - 2025 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:
- 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
Click here
17. DISCONNECT FLOOR WIRE
Click here
18. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
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*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.
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(b) Disconnect the HV battery junction block assembly connector. NOTICE: Insulate the disconnected high-voltage connector with insulating tape. |
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(c) Disconnect the hybrid battery terminal block connector.
NOTICE:
Insulate the disconnected high-voltage connector with insulating tape.
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(d) Remove the bolt and electric vehicle battery plug assembly from the HV battery. |
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(e) Disconnect the 2 HV battery junction block assembly connectors. NOTICE: Insulate the disconnected high-voltage connectors with insulating tape. |
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(f) 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. |
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19. REMOVE HYBRID BATTERY TERMINAL BLOCK
CAUTION:
Be sure to wear insulated gloves and protective goggles.
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(a) Disconnect the hybrid battery terminal block connector. NOTICE: Insulate the disconnected high-voltage connector with insulating tape. |
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(b) Disengage the claw to remove the hybrid battery terminal block from the HV battery. |
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