Toyota RAV4 EV 2013 User manual

RAV4 EV
Electric Vehicle
ELECTRIC VEHICLE
DISMANTLING
MANUAL
QEA38 Series

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Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Toyota RAV4 EV
electric vehicles. RAV4 EV dismantling procedures are similar to other non-electric Toyota vehicles
with the exception of the high voltage electrical system. It is important to recognize and understand the
high voltage electrical system features and specifications of the Toyota RAV4 EV electric vehicle, as
they may not be familiar to dismantlers.
High voltage electricity powers the electric motor, DC/DC converter, battery coolant heater, air
conditioning (A/C) compressor, cabin coolant heater and inverter. All other automotive electrical
devices such as the head lights, radio, and gauges are powered from a separate 12 Volt auxiliary battery.
Numerous safeguards have been designed into the RAV4 EV to help ensure the high voltage,
approximately 386 Volt, Lithium-ion (Li-ion) Electric Vehicle (EV) battery assembly is kept safe and
secure in an accident.
The Li-ion EV battery assembly contains sealed batteries that are similar to rechargeable batteries used
in some battery operated power tools and other consumer products. The electrolyte is absorbed in the
cell plates and will not normally leak out even if the battery is cracked.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
• Toyota RAV4 EV identification.
• Major electric vehicle component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle RAV4 EV electric vehicles
as safely as the dismantling of a conventional non-electric automobile.
©2012 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

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Table of Contents
About the RAV4 EV .....................................................................................................................................1
RAV4 EV Identification ...............................................................................................................................2
Exterior .........................................................................................................................................................3
Interior...........................................................................................................................................................4
Motor Compartment......................................................................................................................................5
Electric Vehicle Component Locations & Descriptions.............................................................................6
Specifications................................................................................................................................................7
Electric Vehicle Operation...........................................................................................................................8
Vehicle Operation..........................................................................................................................................8
Electric Vehicle (EV) Battery Assembly and Auxiliary Battery ...............................................................9
EV Battery Assembly ....................................................................................................................................9
Components Powered by the EV Battery Assembly .....................................................................................9
EV Battery Assembly Recovery ..................................................................................................................10
Auxiliary Battery..........................................................................................................................................10
High Voltage Safety ....................................................................................................................................11
High Voltage Safety System........................................................................................................................11
Service Plug Grip........................................................................................................................................12
Precaution to be observed when dismantling the vehicle........................................................................13
Necessary Items.........................................................................................................................................13
Spills.............................................................................................................................................................14
Dismantling the vehicle..............................................................................................................................15
Removal of EV Battery Assembly .............................................................................................................20
HV Battery Caution Label.........................................................................................................................28

1
About the RAV4 EV
The RAV4 EV continues into its 2nd generation as an electric vehicle. Electric Vehicle means
that the vehicle contains only an electric motor and does not have a gasoline engine for power.
Electricity stored in a high voltage Electric Vehicle (EV) battery assembly for the electric
motor.
The following illustration demonstrates how the RAV4 EV operates in various driving modes.
Utilizing the charge cable assembly connected to a 120/240 Volt outlet, the vehicle’s EV
battery assembly can be fully charged within 40 hours (when charging on 120 Volt / 15
Amp) or 6 hours (when charging on 240 Volt / 40 Amp) from a fully discharged state.
A fully charged RAV4 EV will travel approximately 152 miles (245 km).
During deceleration, such as when braking, the vehicle regenerates kinetic energy from the
front wheels to produce electricity that recharges the EV battery assembly.
While the vehicle is stopped, the electric motor is off, however the vehicle remains on and
operational.
Plug-in Charging Driving

Deceleration
Stopped
Plug-in Charging Electricity
Charging batteries

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RAV4 EV Identification
In appearance, the 2012 model year RAV4 EV is nearly identical to the conventional, non-electric
Toyota RAV4. The RAV4 EV is a 5-door SUV. Exterior, interior, and motor compartment
illustrations are provided to assist in identification.
The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield
cowl and on the left side B pillar.
Example VIN: 2T3YL4DV0C2020211
A RAV4 EV is identified by the first 8 alphanumeric characters 2T3YL4DV.
Left Side Windshield Cowl and Left Side Door Pillar

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RAV4 EV Identification (Continued)
Exterior
and logos on the back door.
logo on the driver and front passenger door.
logo on the front upper grille.
Charge inlet door located on the left side rear quarter panel.
Exterior Left Side View
Exterior Front View and Rear View
Exterior Rear and Left Side View
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RAV4 EV Identification (Continued)
Interior
The instrument cluster (power meter, driving range & battery gauge, READY indicator, plug-in
indicator and warning lights) located in the dash behind the steering wheel, is different than the one
on the conventional, non-electric RAV4.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated
Interior View
Instrument Cluster View
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
Power Meter, Driving Range & Battery Gauge
READY Indicator
Plug-in Indicator

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RAV4 EV Identification (Continued)
Motor Compartment
Logo on the plastic cover.
Orange colored high voltage power cables.
Motor Compartment View
Power Cables
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6
Electric Vehicle Component Locations & Descriptions
Component Location Description
12 Volt Auxiliary
Battery Motor Compartment A lead-acid battery that supplies power to the low voltage devices.
Electric Vehicle (EV)
Battery Assembly Undercarriage 386 Volt Lithium-ion (Li-ion) battery assembly consisting of 3.6 Volt cells connected in a series-parallel circuit.
Power Cables Undercarriage,
Motor
Compartment and
Left Side behind
Rear Quarter
Panel
Orange colored power cables carry high voltage Alternating
Current (AC) between the charge port and on-board charger,
and high voltage Direct Current (DC) between the EV
battery assembly, DC/DC converter, inverter, A/C
compressor, battery coolant heater and cabin coolant heater.
Drive Unit Motor
Compartment The drive unit integrates the inverter, electric motor, differential and p-lock actuator.
Inverter Drive Unit Inverts the high voltage electricity from the EV battery to
3-phase AC electricity that drive the electric motor. Also
converts the high voltage AC power generated by the
electric motor during regeneration to high voltage DC
power to charge the EV battery assembly.
Electric Motor Drive Unit 3-phase high voltage AC inductive electric motor contained
in the drive unit. It is used to power the front wheels.
On-Board Charger 
Motor Compartment Boosts the AC power supplied from an external power source and converts it to DC to charge the EV battery
assembly.
A/C Compressor
(with Inverter) Motor Compartment 3-phase high voltage AC electrically driven motor compressor.
DC/DC
Converter for 12 Volt
Auxiliary Battery 
Motor
Compartment Converts 386 Volts from the EV battery assembly to 12 Volts for low voltage vehicle power.
Cabin Coolant
Heater Motor Compartment Heats the coolant used for the cabin heater.
*Numbers in the component column apply to the illustrations on the following page.

7
Electric Vehicle Component Locations & Descriptions (Continued)
Specifications
Electric Motor: 154 hp (115 kW), AC Inductive Motor
Transaxle: Automatic Only
EV Battery Assembly: 386 Volt Sealed Li-ion Battery
Curb Weight: 4,032 lbs/1,829 kg
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passengers
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