Toyota RAV4 EV 2013 User manual

RAV4 EV
Electric Vehicle
ELECTRIC VEHICLE
DISMANTLING
MANUAL
QEA38 Series

ii
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.

iii
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

2
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

3
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










4
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


Power Meter, Driving Range & Battery Gauge
READY Indicator
Plug-in Indicator

5
RAV4 EV Identification (Continued)
Motor Compartment
Logo on the plastic cover.
Orange colored high voltage power cables.
Motor Compartment View
Power Cables



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

















8
Electric Vehicle Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, as there is no gasoline engine, no sound will be produced from the vehicle. It is
important to recognize and understand the READY indicator provided in the instrument cluster.
When lit, it informs the driver that the vehicle is on and operational even though the motor
compartment is silent.
Vehicle Operation
• With the RAV4 EV, the system is operational while the READY indicator is on.
• Never assume that the vehicle is shut off just because the motor compartment is silent. Always
look for the READY indicator status. The vehicle is shut off when the READY indicator is off.
Instrument Cluster READY Indicator

9
Electric Vehicle (EV) BatteryAssembly and Auxiliary Battery
The RAV4 EV features a high voltage Electric Vehicle (EV) battery assembly that contains sealed
Lithium-ion (Li-ion) battery cells.
EV Battery Assembly
• The EV battery assembly is enclosed in a metal case and is rigidly mounted to the undercarriage.
The metal case is isolated from high voltage.
• The EV battery assembly consists of low voltage (3.6 Volt) Li-ion battery cells connected in a
series-parallel circuit to produce approximately 386 Volts. Each cell is non-spillable and
contained in a sealed metal case.
• The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte
is absorbed into the battery cell separator and will not normally leak, even in a collision.
Components Powered by the EV Battery Assembly
EV Battery Assembly
Battery assembly voltage 386 V
Li-ion battery cell voltage 3.6 V
Li-ion battery cell dimensions Diameter x Height 0.71 x 2.56 in.
(18 x 65 mm)
Li-ion cell weight Approximately 0.1 lbs (46.5 g)
Li-ion battery assembly dimensions
Length x Width x Height 74 x 57 x 11 in. (1876 x 1454 x 270 mm)
Li-ion battery assembly weight 845 lbs (383.5 kg)
• Inverter
•
A/C Compressor
• Power Cables • Cabin Coolant Heater
• DC/DC Converter for 12 VAuxiliary Battery • Battery Coolant Heater

10
Electric Vehicle (EV) BatteryAssembly and Auxiliary Battery (Continued)
EV Battery Assembly Recovery
• Contact either your Toyota Distributor or the nearest Toyota dealer.
Auxiliary Battery
• The RAV4 EV contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers
the vehicle electrical system similar to a conventional vehicle. As with other conventional vehicles,
the negative terminal of the auxiliary battery is grounded to the metal chassis of the vehicle.
• The auxiliary battery is located in the motor compartment.
386 Volt EV Battery Assembly 12 Volt Auxiliary Battery Mounted in Motor Compartment
EV Battery Assembly Mounted in Under the Floor
EV Battery Assembly

11
High Voltage Safety
The EV battery assembly powers the high voltage electrical system with DC electricity. Positive and
negative orange colored high voltage power cables are routed from the EV battery assembly, under the
vehicle floor pan, to the drive unit (inverter and motor) and DC/DC converter. The inverter contains a
circuit that boosts and inverts the 386 Volts DC from the EV battery assembly to 450 Volts AC to
power the motor. Power cables are routed from the DC/DC converter (HV junction block) to each
high voltage component (A/C compressor, battery coolant heater and cabin coolant heater). The
following systems are intended to help keep occupants in the vehicle and emergency responders safe
from high voltage electricity:
High Voltage Safety System
• High voltage fuses provide short circuit protection in the EV battery assembly.
• Positive and negative high voltage power cables connected to the EV battery assembly are
controlled by a 12 Volt contactor (relay) . When the vehicle is shut off and not charging, the
contactor (relay) stops electricity flow from the EV battery assembly.
WARNING:
• The high voltage system may remain powered for up to 10 minutes after
the vehicle is shut off or disabled. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or opening
any orange high voltage power cable or high voltage component.
• Both positive and negative power cables are insulated from the metal body. High voltage
electricity flows through these cables and not through the metal vehicle body. The metal vehicle
body is safe to touch because it is insulated from the high voltage components.
• The battery control computer continuously monitors for high voltage leakage to the metal chassis
while the vehicle is running. If a malfunction is detected, the battery control computer will
illuminate the master warning light in the instrument cluster and indicate “Check EV System”
on the multi-information display.
• The EV battery assembly contactors will automatically open to stop electricity flow in a collision
sufficient to activate the SRS.
*Numbers apply to the illustration on the following page.

12
High Voltage Safety (Continued)
Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 15).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)




AC 3-Phase
Drive Unit
DC/DC Converter
A/C
Compressor
Cabin
Coolant
Heater
Battery
Coolant
Heater
Inverter
Moto
r
Contactor
(Relay)
Main Battery
Battery Control
Computer
On-board
Charger
Charge Point




Drive Unit




Volt DC
Volt DC


HV Junction Block
Volt DC
Volt DC
Volt DC
DC/DC Converter
HV Junction Block
A/C
Compressor
Volt DC
AC 3-Phase
Moto
r
Inverter
Cabin
Coolant
Heater
Battery
Coolant
Heater
Volt DC
On-board
Charger
Main Battery
Volt DC
Volt DC
Volt DC
Charge Point
Contactor
(Relay)
Contactor
(Relay)
Contactor
(Relay)

13
Precaution to be observed when dismantling the vehicle
WARNING:
• The high voltage system may remain powered for up to 10 minutes after
the vehicle is shut off or disabled. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or opening
any orange high voltage power cable or high voltage component.
Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating.
• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
• An electrical tester that is capable of measuring DC 750 Volts or more.

14
Spills
The RAV4 EV contains some of the same common automotive fluids used in other non-electric Toyota
vehicles, with the exception of the Li-ion electrolyte used in the EV battery assembly. The electrolyte
used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the
battery cell separators, even if the battery cells are crushed or cracked, it is unlikely that liquid
electrolyte will leak. Any liquid electrolyte that leaks from a Li-ion battery cell quickly evaporates.
WARNING:
• The Li-ion battery contains organic electrolyte. Only a small amount may leak
from the batteries which may irritate the eyes, nose, throat, and skin.
• Contact with the vapor produced by the electrolyte may irritate the nose and
throat.
• To avoid injury by coming in contact with the electrolyte or vapor, wear
personal protective equipment for organic electrolyte including SCBA or full
face respirator suitable for organic solvents.
• Handle Li-ion electrolyte spills using the following Personal Protective Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are not acceptable for electrolyte
spills.
Butyl rubber or suitable organic solvent gloves.
Apron or protective clothing suitable for organic solvents.
Rubber overboots or boots suitable for organic solvents.
Full face respirator suitable for organic solvents or SCBA.

15
Dismantling the vehicle
The following 5 pages contain general instructions for use when working on a RAV4 EV. Read these
instructions before proceeding to the EV battery removal instructions on page 20.
WARNING:
• The high voltage system may remain powered for up to 10 minutes after
the vehicle is shut off or disabled. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or opening
any orange high voltage power cable or any high voltage component.
1. Shut off the ignition (READY indicator is off).
Then disconnect the cable from the auxiliary
battery negative (-) terminal.
(1) Open the hood.
(2) Disconnect the auxiliary battery negative (-)
terminal.
2. Remove the front upper floor cover.
(1) Slide the passenger seat forward and tilt the
seatback forward.
(2) Remove the carpeting underneath the seat.
(3) Remove the 4 nuts and front upper floor cover.
3. Remove the service plug grip.
Caution:
• Wear insulating gloves and protective goggles.
• Remove the service plug grip to interrupt the high voltage circuit at the time of
inspection or repair.
• After removing the service plug grip, attach a note to it to prevent other
technicians from mistakenly reconnecting it while you are servicing the vehicle.
• All the high voltage wiring connectors are orange.
Notice:
To prevent the electric vehicle battery assembly from being damaged by falling
objects, temporarily install the front upper floor cover after removing the service plug
grip.

16
(1) Using insulating gloves, press the part with the
black claw and pull the handle up slightly to
release the lock.
(2) Press the black-colored tab and lift the handle
upright, then remove the service plug grip by
taking the handle and pulling it directly
upward.
4. Carry the removed service plug grip in your pocket to prevent other staff from accidentally
reinstalling it while you are dismantling the vehicle.
5. Make other staff aware that a high-voltage system is being dismantled by using the
following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 19).
Press
Pull
Upright
Press
Pull

17
6. If the service plug grip cannot be removed due to damage to the vehicle, remove the IG2
fuse (15 A blue colored).
Caution:
This operation shuts off the EV system. Be sure to wear insulated gloves because
high voltage is not shut off inside the EV battery. When it is possible to remove the
service plug grip, remove it and continue the procedure.
7. After disconnecting or exposing a high-voltage
connector or terminal, insulate it immediately
using insulating tape. Before disconnecting or
touching a bare high-voltage terminal, wear
insulated gloves.
8. Check the EV battery assembly and nearby area
for leakage. If you find any liquid, it may be
Li-ion electrolyte. Handle Li-ion electrolyte
spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. Fold down helmet shields are not acceptable for electrolyte
spills.
• Butyl rubber or suitable organic solvent gloves.
• Apron or protective clothing suitable for organic solvents.
• Rubber overboots or boots suitable for organic solvents.
• Full face respirator suitable for organic solvents or SCBA.
Caution:
• The Li-ion battery contains organic electrolyte. Only a small amount may leak
from the batteries which may irritate the eyes, nose, throat, and skin.
• Contact with the vapor produced by the electrolyte may irritate the nose and
throat.
• To avoid injury by coming in contact with the electrolyte or vapor, wear personal
protective equipment for organic electrolyte including SCBA or full face respirator
suitable for organic solvents.
IG2 fuse (15 A blue)