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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 NICKEL METAL HYDRIDE BATTERY) >> Removal [08/2020 - 12/2021] >> Procedure

Removal [08/2020 - 12/2021]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    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 

    Refer to REMOVAL [08/2020 - 12/2021]

  3. DISCONNECT ENGINE ROOM MAIN WIRE 

    See 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 

    Refer to PROCEDURE - Step 6

  7. CONNECT ENGINE ROOM MAIN WIRE 

    See step  31

  8. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 1

  9. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 2

  10. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY 

    Refer to PROCEDURE - Step 10

  11. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 8

  12. REMOVE NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 4

  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 

    Refer to PROCEDURE - Step 6

  15. REMOVE BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 7

  16. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  17. REMOVE NO. 1 HV BATTERY COVER PANEL RH 

    Refer to PROCEDURE - Step 9

  18. DISCONNECT FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 10

  19. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the clamp.
      GTY876682Courtesy 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.
    4. Disengage the 2 clamps to disconnect the floor wire.
      GTY910578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT 

    Refer to PROCEDURE - Step 14

  21. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  22. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Remove the bolt and disconnect the electric vehicle battery plug assembly.
      GTY940874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the HV battery junction block assembly connector.
      GTY904830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected connectors with insulating tape.

    3. Disengage the clamp.
    4. Disengage the 2 claws and open the wiring harness protector.
      GTY940873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the HV battery junction block assembly connector.
      NOTE:

      Insulate the disconnected connectors with insulating tape.

      GTY904842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the wiring harness protector.
      GTY880073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    7. Disconnect the HV battery junction block assembly connector.
      GTY940875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. 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.

      GTY904841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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