HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL; 2024 MY RAV4 HV [10/2023

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM100000002FR7A
Model Year Start: 2024	Model: RAV4 HV	Prod Date Range: [10/2023 - ]
Title: HYBRID / BATTERY CONTROL: FRAME WIRE: 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 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
*: 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
Replacement of air fuel ratio sensor Gas leak from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
- for AWD with NICKEL METAL HYDRIDE BATTERY:
  Click here
- for LITHIUM-ION BATTERY:
  Click here
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.
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.

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 (w/ NO. 1 FLOOR UNDER COVER)

Click here

3. REMOVE SERVICE PLUG GRIP

Click here

4. 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.

5. REMOVE CONNECTOR COVER ASSEMBLY

Click here

6. CHECK TERMINAL VOLTAGE

Click here

7. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

Click here

8. DISCONNECT FLOOR UNDER WIRE

Click here

9. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

Click here

10. REMOVE REAR SEAT CUSHION LOCK HOOK

Click here

11. REMOVE REAR DOOR SCUFF PLATE LH

Click here

12. REMOVE NO. 3 BATTERY SERVICE COVER BOARD

Click here

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

Click here

15. REMOVE BATTERY SERVICE COVER BOARD

Click here

16. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

Click here

17. REMOVE NO. 1 HV BATTERY COVER PANEL RH

Click here

18. DISCONNECT 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.

(d) Remove the nut.

(e) Disengage the clamp.

(f) Disengage the clamp and disconnect HV floor under wire.

19. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH

Click here

20. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH

Click here

21. REMOVE NO. 1 ENGINE UNDER COVER

Click here

22. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

Click here

23. REMOVE ENGINE UNDER COVER HEAT INSULATOR

Click here

24. REMOVE FRONT FLOOR COVER LH

Click here

25. REMOVE FRONT FLOOR COVER RH

Click here

26. REMOVE FRONT CENTER FLOOR COVER

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

27. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR

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

28. REMOVE FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

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

29. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

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

30. REMOVE NO. 2 ENGINE SERVICE COVER CUSHION

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

31. REMOVE ENGINE SERVICE COVER CUSHION

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

32. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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

33. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click here

34. REMOVE EXHAUST MANIFOLD

Click here

35. REMOVE FUEL TANK ASSEMBLY

Click here

36. REMOVE FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Insulate the disconnected connectors with insulating tape.

(a) Remove the 2 nuts snd 2 bolts.

	Bolt
	Nut

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

(d) Remove the 2 stud clamps.

NOTICE:

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

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

NOTICE:

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

(f) Disengage the 2 claws.

Remove in this Direction

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

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

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

(j) Disengage the clamp.

(k) 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