HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL; 2023 MY RAV4 HV [10/2022

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000026Q3I
Model Year Start: 2023	Model: RAV4 HV	Prod Date Range: [10/2022 - 10/2023]
Title: HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL; 2023 MY RAV4 HV [10/2022 - 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
	Back door lock initialization	Power door lock control system

CAUTION:

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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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. 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 SERVICE PLUG GRIP

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3. DISCONNECT ENGINE ROOM MAIN WIRE

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4. REMOVE CONNECTOR COVER ASSEMBLY

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5. CHECK TERMINAL VOLTAGE

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6. INSTALL CONNECTOR COVER ASSEMBLY

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7. CONNECT ENGINE ROOM MAIN WIRE

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8. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

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9. REMOVE REAR SEAT CUSHION LOCK HOOK

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10. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

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11. REMOVE REAR DOOR SCUFF PLATE LH

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12. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

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13. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

14. REMOVE NO. 2 BATTERY SERVICE COVER BOARD

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15. REMOVE BATTERY SERVICE COVER BOARD

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16. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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17. REMOVE NO. 1 HV BATTERY COVER PANEL RH

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18. DISCONNECT FLOOR UNDER WIRE

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19. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

*a	Electric Vehicle Battery Plug Assembly Connector
*b	HV Battery Junction Block Assembly Connector

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

(d) Disengage the 2 clamps to disconnect the floor wire.

20. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

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21. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

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22. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the bolt and disconnect the electric vehicle battery plug assembly.

(b) Disconnect the HV battery junction block assembly connector.

NOTICE:

Insulate the disconnected connectors with insulating tape.

(d) Disengage the 2 claws and open the wiring harness protector.

(e) Disconnect the HV battery junction block assembly connector.

NOTICE:

Insulate the disconnected connectors with insulating tape.

(f) Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the wiring harness protector.

*a	Protective Tape

(g) Disconnect the HV battery junction block assembly connector.

(h) 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.