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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 9 (Hybrid Battery Control System - Service Information (6 Of 7)) >> HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY) >> Removal [10/2023 - ] >> Procedure

Removal [10/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [10/2023 - ]

  2. DISCONNECT ENGINE ROOM MAIN WIRE 

    See step  4

  3. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  4. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 10

  5. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  6. CONNECT ENGINE ROOM MAIN WIRE 

    See step  31

  7. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 2

  9. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 9

  10. REMOVE NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 4

  11. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  12. REMOVE NO. 2 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 6

  13. REMOVE BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 7

  14. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  15. REMOVE NO. 1 HV BATTERY COVER PANEL RH 

    Refer to PROCEDURE - Step 9

  16. 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.

      GTY996775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
    2. Disconnect the shield ground from the HV battery.
  17. DISCONNECT FLOOR WIRE 

    Refer to PROCEDURE - Step 11

  18. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. GTY1106946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      1. for Type A:

        Disengage the 2 claws and open the wiring harness protector.

      2. for Type B:

        Disengage the claw and open the wiring harness protector.

    2. Disconnect the HV battery junction block assembly connector.
      GTY996593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected high-voltage connector with insulating tape.

    3. Disconnect the hybrid battery terminal block connector.
      NOTE:

      Insulate the disconnected high-voltage connector with insulating tape.

    4. Remove the bolt and electric vehicle battery plug assembly from the HV battery.
      GTY996589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the 2 HV battery junction block assembly connectors.
      GTY996598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected high-voltage connectors with insulating tape.

    6. GTY1105762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Type A *B for Type B
      *a Protective Tape - -
      1. for Type A:

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

      2. for Type B:

        Using a screwdriver with its tip wrapped with protective tape, disengage the claw and remove the wiring harness protector.

    7. Remove the 4 nuts and HV battery junction block assembly from the HV battery.
      NOTE:

      If the HV battery junction block assembly has been struck or dropped, replace it with a new one.

      GTY995994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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