| Last Modified: 05-08-2025 | 6.11:8.1.0 | Doc ID: RM100000001OE66 |
| Model Year Start: 2020 | Model: RAV4 HV | Prod Date Range: [06/2020 - ] |
| Title: HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): INSTALLATION; 2020 - 2025 MY RAV4 HV [06/2020 - ] | ||
INSTALLATION
PROCEDURE
1. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
(a) Install the HV battery junction block assembly to the HV battery with the 4 nuts.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
NOTICE:
If the HV battery junction block assembly has been struck or dropped, replace it with a new one.
(b) for Type A:
Engage the 2 claws to install the wiring harness protector.
for Type B:
Engage the claw to install the wiring harness protector.
(c) Connect the 2 HV battery junction block assembly connectors.
NOTICE:
Make sure that the connectors are connected securely.
(d) Install the electric vehicle battery plug assembly to the HV battery with the bolt.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
(e) Connect the hybrid battery terminal block connector.
NOTICE:
Make sure that the connector is connected securely.
(f) Connect the HV battery junction block assembly connector.
NOTICE:
Make sure that the connector is connected securely.
(g) for Type A:
Engage the 2 claws to close the wiring harness protector.
for Type B:
Engage the claw to close the wiring harness protector.
2. CONNECT FLOOR WIRE
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![2020 - 2025 MY RAV4 HV [06/2020 - ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): INSTALLATION+](/t3Portal/stylegraphics/info.gif)
3. CONNECT FLOOR UNDER WIRE
CAUTION:
Be sure to wear insulated gloves.
(a) Connect the shield ground to the HV battery.
(b) Connect the 2 HV battery junction block assembly connectors.
NOTICE:
Make sure that the connectors are connected securely.
4. INSTALL NO. 1 HV BATTERY COVER PANEL RH
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5. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY
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6. INSTALL BATTERY SERVICE COVER BOARD
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7. INSTALL NO. 2 BATTERY SERVICE COVER BOARD
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8. INSTALL REAR DOOR SCUFF PLATE RH
HINT:
Use the same procedure as for the LH side.
Click here
9. INSTALL NO. 3 BATTERY SERVICE COVER BOARD
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10. INSTALL REAR DOOR SCUFF PLATE LH
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11. INSTALL REAR SEAT CUSHION LOCK HOOK
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12. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY
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13. INSTALL SERVICE PLUG GRIP
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14. PERFORM CURRENT SENSOR OFFSET LEARNING
HINT:
Perform this procedure when the HV battery junction block assembly or battery ECU assembly has been replaced.
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (READY).
(c) Perform a road test.
NOTICE:
Accelerate and decelerate gently. Avoid rapid acceleration and deceleration.
(1) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid/EV Battery Current.
Powertrain > Hybrid Control > Data List
|
Tester Display |
|---|
|
Hybrid/EV Battery Current |
(2) Drive the vehicle with the value of Data List item "Hybrid/EV Battery Current" between -50 A and 50 A.
HINT:
Distance and driving time are not specified.
(3) Turn the power switch off and leave the vehicle for 30 seconds or more.
(4) Turn the power switch on (IG).
(5) Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid/EV Battery Current.
Powertrain > Hybrid Control > Data List
|
Tester Display |
|---|
|
Hybrid/EV Battery Current |
(6) Check that the value of "Hybrid/EV Battery Current" is between -0.5 A and 0.5 A with the power switch on (IG).
NOTICE:
If the value is outside the specified range, perform the road test again.
HINT:
- When the power switch is on (IG), if value of "Hybrid/EV Battery Current" is between -0.5 A and 0.5 A, current sensor offset learning has been completed.
- Even if the current sensor offset learning is not complete, the current sensor value will be corrected by repeating the road test a maximum of 7 times.
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