T-TT-0228-13

Tech Tip
T-TT-0228-13
March 10, 2014
RAV4 EV
CONDITION
Below are step-by-step instructions on how to remove and install the Service Plug .
NOTE : If these steps are not followed , it's possible to damage the Service Plug installation/removal
mechanism .
WARNING: Make sure that the locking lever is vertically positioned before reinstalling the Plug .
Please refer to the Toyota RAV4 EV Repair Manual section for precautions when working on high
voltage components/systems . Links to the Repair Maual are located at the end of this document.
2012 RAV4 EV (RM19QOU):
Engine/Hybrid System\HYBRID I BATTERY CONTROL\HYBRID CONTROL
SYSTEM\PRECAUTION (2012 RAV4 EV): HYBRID I BATTERY CONTROL: HYBRID CONTROL
SYSTEM
2013 RAV4 EV (RM251 OU):
Engine/Hybrid System\HYBRID I BATTERY CONTROL\HYBRID CONTROL
SYSTEM\PRECAUTION; 2013 MY RAV4 EV [12/2012 ]
Some of the information from the Repair Manual is repeated below for quick reference:
PRECAUTION
1. PRECAUTIONS FOR INSPECTING ELECTRIC VEHICLE CONTROL SYSTEM
(a) Before inspecting the high-voltage system or disconnecting the low voltage connector of the electric
vehicle traction motor assembly (inverter), DC/DC converter assembly, electric vehicle battery
assembly or electric vehicle charger assembly, take safety precautions such as wearing insulated
gloves and protective goggles, and removing the service plug grip to prevent electrical shocks. After
removing the service plug grip, attach a note to it to prevent other technicians from mistakenly
reconnecting it while you are working on the high-voltage system.
Expires on
Ver 2 1 8128/2011 T
03/10/2015
Rev1
© 2013 , Toyota Motor Sales , USA
Page 1 of 6
Tech Tip
T-TT-0228-13
March 10, 2014
NOTICE:
•
•
After turning the power 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.
After removing the service plug grip, turning the power switch on (READY) may cause a
malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.
(b) After removing the service plug grip, wait for at least 10 minutes before touching any of the highvoltage connectors or terminals .
CAUTION:
Wear insulated gloves and protective goggles.
HINT:
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the electric
vehicle traction motor assembly (inverter), DC/DC converter assembly, electric vehicle battery
assembly and electric vehicle charger assembly.
03/10/2015
Ver . 2 1 8/28/2011 T
Rev1
© 2013 , Toyota Motor Sales , USA
Page 2 of 6
Tech Tip
T-TT-0228-13
March 10, 2014
REMOVAL INSTRUCTIONS:
1. Fold back the carpet below the passenge r seat (from
the right rear floo r) .
2. Remove the 4 nuts (10 mm socket) and remove the
cover over the EV Battery Service Plug .
03/10/2015
Ver 2.1 8128/201 1 T
Rev1
© 2013 , Toyota Motor Sa les, USA
Page 3 of 6
Tech Tip
T-TT-0228-13
March 10, 2014
3. To remove the Service Plug, first (1) press the inner
release tab (see red arrow in picture) . While holding
the tab pressed with one hand , use the other hand to
pull up (2) on the outer lever (see blue arrow) .
4 . After the outer lever is up approximately 45 degrees , (1)
press the inner release tab (see red arrow in picture).
While holding the tab pressed with one hand , use the
other hand to pull up (2) on the outer lever (see blue
arrow) until the outer lever is in the full up position (see
second picture) .
03/10/20 15
Ver 2.1 812812011 T
Rev1
© 201 3, Toyota Motor Sales, USA
Page 4 of 6
Tech Tip
T-TT-0228-13
March 10, 2014
5. Pull straight up on the outer handle to remove the
service plug.
03/10/2015
Ver 2 1 8128120 11 T
Rev1
© 2013 , Toyota Motor Sa les, USA
Page 5 of 6
Tech Tip
T-TT-0228-13
Ma rch 10, 2014
INSTALLATION INSTRUCTIONS:
WARNING : Make sure that the locking lever is vertically positioned before reinstalling the Plug. If the
locking lever is in the half-way open position (45 degrees) and the Service Plug is
reinstalled in the vehicle , the vehicle may not READY-ON , because the Service Plug is
not properly installed .
1. Fully seat the Service Plug in its mounting location (make sure that the locking lever is vertically
positioned in its fully open position) .
2 . Push the locking lever down until it's fully seated in the horizontal position .
LINK REFERENCES
•
•
HYBRID I BATTERY CONTROL: HYBRID CONTROL SYSTEM : PRECAUTION (2012 RAV4
EV)
HYBRID I BATTERY CONTROL: HYBRID CONTROL SYSTEM : PRECAUTION ; 2013 MY
RAV4 EV (12/2012 - ???????]
03/10/2015
Ver. 2 1 812812011 T
Rev1
© 2013 , Toyota Motor Sales , USA
Page 6 of 6