Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001HFIM
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [02/2019 - 10/2019]
Title: HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL; 2019 MY RAV4 HV [02/2019 - 10/2019]

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 2019 - 2022 MY RAV4 HV [02/2019 - 10/2022]; 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

2019 - 2021 MY RAV4 RAV4 HV [11/2018 - 12/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system*

Pre-collision system

Lighting system (EXT)(w/ AFS)

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY RAV4 RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY RAV4 HV [11/2018 - 10/2022]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Reset back door close position

Power back door system

2019 - 2023 MY RAV4 HV [11/2018 - 10/2023]; DOOR / HATCH: POWER BACK DOOR SYSTEM (for HV Model): 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.

w/ Canister Pump Module: 2019 MY RAV4 RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/ Canister Pump Module): INITIALIZATION

w/o Canister Pump Module: 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM (w/o Canister Pump Module): 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 2WD:

      Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for 2WD with NICKEL METAL HYDRIDE BATTERY): PRECAUTION

    • for AWD:

      Click here 2019 - 2024 MY RAV4 HV [02/2019 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for AWD with NICKEL METAL HYDRIDE 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 radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) auxiliary battery terminal.

Waiting Time before Disconnecting Cable from Negative (-) Auxiliary Battery Terminal

System Name

See Procedure

Vehicle enrolled in Toyota Entune system or safety connect system

6 minutes

Vehicle not enrolled in Toyota Entune system and safety connect system

1 minute

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 (for AWD, w/ NO. 1 FLOOR UNDER COVER)

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 06/2020]; REAR SUSPENSION: REAR SUSPENSION MEMBER (for HV Model AWD): REMOVAL+

3. REMOVE SERVICE PLUG GRIP

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

4. REMOVE NO. 2 INVERTER PROTECTOR (for AWD, w/ NO. 2 INVERTER PROTECTOR)

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for AWD): REMOVAL+

5. 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.

6. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for 2WD): REMOVAL+

7. CHECK TERMINAL VOLTAGE

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for 2WD): REMOVAL+

8. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for 2WD): REMOVAL+

9. DISCONNECT HV FLOOR UNDER WIRE

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER (for 2WD): REMOVAL+

10. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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

11. REMOVE REAR SEAT CUSHION LOCK HOOK

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

12. REMOVE REAR DOOR SCUFF PLATE LH

Click here 2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

13. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

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

14. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

15. REMOVE NO. 2 BATTERY SERVICE COVER BOARD

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

16. REMOVE BATTERY SERVICE COVER BOARD

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

17. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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

18. REMOVE NO. 1 HV BATTERY COVER PANEL RH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

19. DISCONNECT HV 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.

20. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

21. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

22. REMOVE NO. 1 ENGINE UNDER COVER

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

23. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

24. REMOVE ENGINE UNDER COVER HEAT INSULATOR

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

25. REMOVE FRONT FLOOR COVER LH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

26. REMOVE FRONT FLOOR COVER RH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

27. REMOVE FRONT CENTER FLOOR COVER

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

28. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR

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

29. REMOVE FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

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

30. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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

31. REMOVE NO. 2 ENGINE SERVICE COVER CUSHION

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

32. REMOVE ENGINE SERVICE COVER CUSHION

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

33. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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

34. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL+

35. REMOVE EXHAUST MANIFOLD

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL+

36. REMOVE FUEL TANK ASSEMBLY

  • w/ Canister Pump Module:

    Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (FUEL): FUEL TANK (w/ Canister Pump Module): REMOVAL

  • w/o Canister Pump Module:

    Click here 2019 - 2020 MY RAV4 HV [11/2018 - 08/2020]; A25A-FXS (FUEL): FUEL TANK (w/o Canister Pump Module): REMOVAL

37. REMOVE HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Insulate the disconnected connectors with insulating tape.

(a) for 2WD:

*A

for 2WD

*B

for AWD

Bolt

Nut

(1) Remove the 2 nuts.

(b) for AWD:

(1) Remove the 2 nuts snd 2 bolts.

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

(d) Remove the 3 bolts and nut.

(e) Remove the 2 stud clamps.

NOTICE:

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

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

NOTICE:

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

(g) Disengage the 2 claws.

Remove in this Direction

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

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

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

(k) for AWD:

(1) Disengage the clamp.

(2) 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