HYBRID / BATTERY CONTROL: BATTERY ECU (for LITHIUM-ION BATTERY): REMOVAL; 2024 MY RAV4 HV [10/2023

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FR6Y
Model Year Start: 2024	Model: RAV4 HV	Prod Date Range: [10/2023 - ]
Title: HYBRID / BATTERY CONTROL: BATTERY ECU (for LITHIUM-ION BATTERY): REMOVAL; 2024 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 battery ECU 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
	Power back door initialization	Power door lock control system
Replacement of battery ECU assembly	Current sensor offset learning	DTCs are stored

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
Click here
To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:

The type of battery ECU assembly to be used varies depending on the vehicle model.

The type of battery ECU assembly can be confirmed by the color of the label.

*a	Black Label

If the wrong type of battery ECU assembly is installed, the power switch cannot be turned on (READY).
After installing the battery ECU assembly, perform the following to check that the power switch can be turned on (READY).
- Turn the power switch on (READY).
- Turn the power switch off and wait for 30 seconds or more.
- Turn the power switch on (READY) again.
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. WHEN REPLACING BATTERY ECU ASSEMBLY

HV battery learning values are stored in the battery ECU assembly and ECM and are used to detect malfunctions and illuminate the hybrid battery indicator light in the combination meter assembly. When either of these ECUs is replaced, the new ECU receives the HV battery learning values from the other ECU and stores them.

NOTICE:

Do not replace the battery ECU assembly and ECM at the same time as the HV battery learning values will be lost. However, if it is necessary to replace both ECUs at the same time, replace them by following the procedure below.
Do not replace the battery ECU assembly or ECM with a used one from another vehicle.

(a) Procedure when replacing both battery ECU assembly and ECM:

(1) Disconnect the cable from the negative (-) auxiliary battery terminal.

(2) Replace either ECU.

(3) Connect the cable to the negative (-) auxiliary battery terminal.

(4) Turn the power switch on (READY) and wait for 5 minutes or more.

(5) Turn the power switch off and disconnect the cable from the negative (-) auxiliary battery terminal.

(6) Replace the other ECU.

(7) Connect the cable to the negative (-) auxiliary battery terminal.

(8) Check that the power switch can be turned on (READY).

HINT:

If the battery ECU assembly and ECM are replaced at the same time without following the above procedure, replace either of the ECUs with its original one and then replace it again by following the above procedure. If the correct procedure is not followed, perform the procedure again from the beginning.

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. REMOVE HYBRID BATTERY HOSE ASSEMBLY

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19. DISCONNECT FLOOR WIRE

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20. REMOVE NO. 4 HV BATTERY PROTECTOR

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21. DISCONNECT FLOOR WIRE

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22. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the 5 bolts, 6 nuts and upper HV battery cover sub-assembly from the HV battery.

*a	Bolt
*b	Nut

23. REMOVE NO. 1 HV BATTERY HOSE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the 2 clips.

(b) Disengage the 2 claws to remove the No. 1 HV battery hose from the HV battery.

24. REMOVE BATTERY ECU ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Disengage the clamp.

(b) Move the lock lever while pushing the lock, and disconnect the 3 battery ECU assembly connectors.

NOTICE:

Make sure to release the lock of the lock lever before moving it.

*a	Lever Lock

If the connector cannot be disconnected, check if the lock lever is completely unlocked.
Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

NOTICE:

If the battery ECU assembly has been struck or dropped, replace it.