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Home >> Toyota >> 2022 >> RAV4 LE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (4 Of 7)) >> HV BATTERY (for NICKEL METAL HYDRIDE BATTERY) >> Removal [10/2023 - ] >> Procedure

Removal [10/2023 - ]: 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 [10/2023 - ]

  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.

      GTY858026Courtesy 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.
      GTY865362Courtesy 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.
      GTY933129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
      NOTE:

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

    2. Disconnect the shield ground from the HV battery.
  11. 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.
  12. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY 

    Refer to PROCEDURE - Step 10

  13. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. GTY910578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 2 clamps to disconnect the floor wire.

  14. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the clip.
      GTY910943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw to remove the No. 1 hybrid battery exhaust duct from the HV battery.
  15. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disconnect the battery voltage sensor connector.
      GTY910944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE HV BATTERY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 5 bolts and HV battery from the vehicle body.
      GTY942223Courtesy 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.
  17. REMOVE UPPER NO. 2 HV BATTERY CARRIER BRACKET 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 12 nuts and upper No. 2 HV battery carrier bracket from the HV battery.
      GTY910954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY 

    See step  3

  19. REMOVE NO. 1 HV BATTERY SHIELD PANEL 

    See step  4

  20. REMOVE BATTERY VOLTAGE SENSOR 

    See step  5

  21. REMOVE HYBRID BATTERY TERMINAL BLOCK 

    Refer to PROCEDURE - Step 5

  22. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 

    Refer to PROCEDURE - Step 22

  23. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  24. REMOVE NO. 1 HV BATTERY INTAKE DUCT LH 

    Refer to PROCEDURE - Step 6

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