HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): INSTALLATION; 2019 - 2025 MY RAV4 HV [11/2018

Last Modified: 05-08-2025	6.11:8.1.0	Doc ID: RM100000001FH9K
Model Year Start: 2019	Model: RAV4 HV	Prod Date Range: [11/2018 - ]
Title: HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): INSTALLATION; 2019 - 2025 MY RAV4 HV [11/2018 - ]

INSTALLATION

PROCEDURE

1. INSPECT NO. 1 HV BATTERY INTAKE FILTER

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2. INSTALL NO. 1 HV BATTERY INTAKE DUCT LH

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3. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

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4. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

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5. INSTALL HYBRID BATTERY TERMINAL BLOCK

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6. INSTALL BATTERY VOLTAGE SENSOR

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7. INSTALL NO. 1 HV BATTERY SHIELD PANEL

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8. INSTALL UPPER HV BATTERY COVER SUB-ASSEMBLY

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9. INSTALL UPPER NO. 2 HV BATTERY CARRIER BRACKET

CAUTION:

Be sure to wear insulated gloves.

(a) Install the upper No. 2 HV battery carrier bracket to the HV battery with the 12 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

10. INSTALL HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the HV battery to the vehicle body with the 4 bolts (A), bolt (B).

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

NOTICE:

Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.
To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
Use cardboard or another similar material to protect the HV battery and vehicle body from damage.
Since the HV battery is very heavy, 2 people are needed to install it. When installing the HV battery, be careful not to damage the parts around it.
When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
While lowering the HV battery into the vehicle, do not allow it to contact the vehicle.
As bolts with 3 different lengths are used, make sure to install each bolt to the correct position.
If the HV battery has been struck or dropped, replace it.

Bolt (A)

(Bolt Length: 25 mm (0.984 in.))

Bolt (B)

(Bolt Length: 24 mm (0.945 in.))

11. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the battery voltage sensor connector.

12. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the claw to install the No. 1 hybrid battery exhaust duct to the HV battery.

(b) Install the clip.

13. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the 2 clamps.

14. INSTALL NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

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15. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the HV battery junction block assembly connector.

(b) Connect the electric vehicle battery plug assembly connector.

16. CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the shield ground to the HV battery.

*a	Shield Ground

(b) Connect the 2 HV battery junction block assembly connectors.

NOTICE:

Make sure that the connectors are connected securely.

17. INSTALL NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 1 HV battery cover panel RH to the HV battery with the 3 bolts and 3 nuts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

*1	Battery Cover Lock Striker
*a	Button
*b	Push

(b) Install the battery cover lock striker, then push the button to lock it.

18. INSTALL BATTERY COOLING BLOWER ASSEMBLY

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19. INSTALL SERVICE PLUG GRIP

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20. PERFORM INITIALIZATION

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