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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Hybrid Battery Control System - Service Information (5 Of 7)) >> HV BATTERY (for LITHIUM-ION BATTERY) >> Removal [06/2020 - 08/2020] >> Procedure

Removal [06/2020 - 08/2020]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. READ VALUE USING TECHSTREAM 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / Hybrid Control / Data List / Hybrid/EV Battery Temperature 1 to 6.

      Powertrain > Hybrid Control > Data List 

      Tester Display
      Hybrid/EV Battery Temperature 1
      Hybrid/EV Battery Temperature 2
      Hybrid/EV Battery Temperature 3
      Hybrid/EV Battery Temperature 4
      Hybrid/EV Battery Temperature 5
      Hybrid/EV Battery Temperature 6
    4. Read the Data List.
      NOTE:

      If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [06/2020 - 08/2020]

  3. DISCONNECT ENGINE ROOM MAIN WIRE 

    Refer to PROCEDURE - Step 4

  4. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  5. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 10

  6. INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

      Torque: 4.5 N.m (46 kgf/cm, 40 in.lbf) 

      NOTE:

      Do not touch the waterproof seal of the connector cover assembly.

      GTY994124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
    2. Install the bolt (B).

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  7. CONNECT ENGINE ROOM MAIN WIRE 

    Refer to PROCEDURE - Step 31

  8. REMOVE BATTERY COOLING BLOWER ASSEMBLY 

    Refer to REMOVAL [11/2018 - ]

  9. REMOVE NO. 1 HV BATTERY COVER PANEL RH 
    WARNING:

    Be sure to wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker.
      GTY996268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *a Projection
      *b Turn
      *c Button

      HINT: 

      Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.

    2. Remove the 3 bolts, 3 nuts and No. 1 HV battery cover panel RH from the HV battery.
  10. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disconnect the 2 HV battery junction block assembly connectors.
      NOTE:

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

      GTY996788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
    2. Disconnect the shield ground from the HV battery.
  11. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the clamp.
      GTY995904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Electric Vehicle Battery Plug Assembly Connector
      *b HV Battery Junction Block Assembly Connector
    2. Disconnect the electric vehicle battery plug assembly connector.
    3. Disconnect the HV battery junction block assembly connector.
  12. REMOVE HYBRID BATTERY HOSE ASSEMBLY 
    1. Disconnect the hybrid battery hose assembly from the vehicle body.
      GTY996466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws to remove the hybrid battery hose assembly from the HV battery.
  13. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY 

    Refer to PROCEDURE - Step 6

  14. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the 2 clamps to disconnect the floor wire.
      GTY995854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 4 HV BATTERY PROTECTOR 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the clamp to remove the No. 4 HV battery protector from the HV battery.
      GTY996469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disconnect the HV battery connector.
      GTY996468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE HV BATTERY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 4 bolts.
      GTY995969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.
      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
      • Use cardboard or another similar material to protect the HV battery and vehicle body from damage.
      • Since the HV battery is very heavy, 2 people are needed to remove it. When removing the HV battery, be careful not to damage the parts around it.
      • When removing the HV battery from the vehicle, do not allow it to contact the vehicle.
      • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
      • Insulate the disconnected terminals or connectors with insulating tape.
      • If the HV battery has been struck or dropped, replace it.
    2. Disengage the 2 guide pins to remove the HV battery from the vehicle body.
      GTY996568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE HOLE PLUG 

    HINT: 

    This procedure is only performed when the hole plug is being replaced with a new one.

    1. Remove the hole plug from the vehicle body.
      GTY996905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. PERFORM RECOVERY INSPECTION 
    1. Before returning the HV battery, make sure to perform a recovery inspection.

      Refer to RECOVERY INSPECTION [06/2020 - ] 

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