NHTSA ID Number: 10133736
Manufacturer Communication Number: T-TT-0228-13
TSB/Document Date: 2018-04-23
Summary
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.
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TSB/Document ID: T-TT-0228-13
Replacement Service Bulletin Number:
MFR Communication Date: 2014-03-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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C2) TOYOTA
Tech Tip T-TT-0228-13 March 10, 2014
EV Battery Service Plug - Installation/Removal
Instructions
e/Hybrid System Meera Control System
7 p
iva ean
APPLICABLE VEHICLES
2012-2013 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.
RECOMMENDATIONS
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 (RM19Q0U):
Engine/Hybrid System\HYBRID / BATTERY CONTROL\HYBRID CONTROL
SYSTEM\PRECAUTION (2012 RAV4 EV): HYBRID / BATTERY CONTROL: HYBRID CONTROL
SYSTEM
2013 RAV4 EV (RM2510U):
Engine/Hybrid System\HYBRID / 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 03/10/2015 = Rev1 © 2013, Toyota Motor Sales, USA Page 1 of 6
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GTOYOTA
tr
EV Battery Service Plug - Installatio
Instructions
Tech Tip T-1T-0228-13 March 30: 2014
nae a
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.
e 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 high-
voltage 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 = Revi © 2013, Toyota Motor Sales, USA
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Page 2 of 6
GP TOYOTA Tech Tip T-TT-0228-13 ace hao
Der
EV Battery Service Plug - Instaliation/Removal a
Instructions
RAV4 EV
REMOVAL INSTRUCTIONS:
1. Fold back the carpet below the passenger seat (from
the right rear floor).
2. Remove the 4 nuts (10 mm socket) and remove the
cover over the EV Battery Service Plug.
03/10/2015 Rev1 © 2013, Toyota Motor Sales, USA Page 3 of 6
Ver 21 w2a7011 7
Tech Tip T-1T-0228-13 eS
Eto]
EV Battery Service Plug - Installation/Removal
Instructions
aN cea
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).
03/10/2015 = Rev1 © 2013, Toyota Motor Sales, USA Page 4 of 6
Ver 20 aaron T
Tech Tip T-TT-0228-13
EV Battery Service Plug - Installation/Removal
Instructions
RAV4 EV
March 10, 2014
5. Puil straight up on the outer handle to remove the
service plug.
03/10/2015
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Rev1
© 2013, Toyota Motor Sales, USA
Page 5 of 6
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