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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid XSE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System (PHEV) - Service Information (1 Of 3) >> Electric Vehicle Converter >> Removal [06/2020 - 12/2021] >> Procedure

Removal [06/2020 - 12/2021]: Procedure

  1. PRECAUTION 
    NOTE:

    After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [06/2020 - 10/2022]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [06/2020 - 12/2021]

  3. REMOVE NO. 2 INVERTER PROTECTOR 

    See step  8

  4. REMOVE CONNECTOR COVER ASSEMBLY 

    See step  9

  5. CHECK TERMINAL VOLTAGE 

    See step  10

  6. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 8

  7. INSTALL NO. 2 INVERTER PROTECTOR 

    See step  14

  8. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 7

  9. REMOVE NO. 3 BATTERY SERVICE COVER BOARD 
    1. Remove the 2 clips (A).
      GTY997520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip (A)
      *b Clip (B)
      *c Clip (C)
    2. Disengage the 3 clips (B), 2 clips (C) and guide to remove the No. 3 battery service cover board.
  10. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure described for the LH side.

  11. REMOVE NO. 2 BATTERY SERVICE COVER BOARD 
    1. Remove the 2 clips (A).
      GTY997206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip (A)
      *b Clip (B)
      *c Clip (C)
    2. Disengage the 3 clips (B), 2 clips (C) and guide to remove the No. 2 battery service cover board.
  12. REMOVE BATTERY SERVICE COVER BOARD 
    1. Pull the battery service cover board in the direction indicated by the arrow (1) shown in the illustration to disengage the 2 clips.
      GTY998199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
    2. Pull the battery service cover board in the direction indicated by the arrow (2) shown in the illustration to disengage the 2 guides to remove it from the rear seat cushion leg sub-assembly.
  13. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 
    1. Remove the 7 bolts.
      GTY997585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Pull in the direction of the arrow in the illustration and detach the 2 guides and remove the rear seat cushion leg sub-assembly.
  14. REMOVE NO. 1 DC/DC CONVERTER INTAKE DUCT 
    1. Lift up the rear seat garnish RH in the direction of the arrow shown in the illustration to the position where the clip shown in the illustration can be seen.
      NOTE:

      Do not lift up the rear seat garnish RH too far to avoid deforming or damaging the rear seat garnish RH.

      GTY1176859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip.
    3. Disengage the clip and guide to remove the No. 1 DC/DC converter intake duct.
      GTY1176857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE DC/DC CONVERTER COOLING EXHAUST DUCT 
    1. Disconnect the connector.
      GTY997052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 3 clamps.
    3. Remove the 2 bolts and DC/DC converter cooling exhaust duct from the DC/DC converter cooling blower assembly.
      GTY997056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 2 HV FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the 2 claws and open the No. 2 HV floor under wire terminal cover.
      GTY997072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut.
      GTY995916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
    3. Disengage the clamp and disconnect the No. 2 HV floor under wire from the DC/DC converter assembly.
    4. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the DC/DC converter assembly connector.
  17. REMOVE DC/DC CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. GTY997071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect the connector.

    2. Disengage the clamp.
    3. Remove the 5 bolts and DC/DC converter assembly with DC/DC converter cooling blower assembly and DC/DC converter bracket.
      GTY997080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the DC/DC converter assembly has been struck or dropped, replace it.

  18. REMOVE DC/DC CONVERTER COOLING BLOWER ASSEMBLY 
    1. Disengage the clamp.
      GTY997067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and DC/DC converter cooling blower assembly.
      NOTE:
      • Be sure not to touch the fan part of the DC/DC converter cooling blower assembly.
      • Do not lift the DC/DC converter cooling blower assembly using the wire harness.
      • Do not allow any foreign matter to enter the DC/DC converter cooling blower assembly.
  19. REMOVE DC/DC CONVERTER BRACKET 
    WARNING:

    Be sure to wear insulated gloves.

    1. GTY997079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 4 bolts and DC/DC converter bracket from the DC/DC converter assembly.

      NOTE:

      If the DC/DC converter assembly has been struck or dropped, replace it.

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