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HOMESERVICE MANUALSTOYOTA2020RAV4 XLE, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 9 (HYBRID BATTERY CONTROL SYSTEM - SERVICE INFORMATION (6 OF 7))FRAME WIREINSTALLATION [08/2020 - ]PROCEDURE
2020 Toyota RAV4 XLE, AWD

Installation [08/2020 - ]: Procedure

2020 Toyota RAV4 XLE, AWDSECTION Procedure
WARNING: This page is about a different variant/trim than selected.
  1. INSTALL FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Install the HV floor under wire to the rear traction motor with transaxle assembly with the 2 bolts.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      NOTE:
      • Make sure that the connector is fully engaged.
      • Do not damage the terminals, interlock connector or rear traction motor with transaxle assembly during installation.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not allow any foreign matter or water to enter the rear traction motor with transaxle assembly.
      • Although the connector may feel loose, this is not due to a malfunction.
      GTY909024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Engage the clamp.
      GTY842515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the HV floor under wire into the floor panel hole and engage the grommet.
      GTY892708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 nuts and 2 bolts.
      GTY1002243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    5. Install a new 2 stud clamps.
      GTY892732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 3 bolts and nut.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    7. Install a new 2 stud clamps.
      GTY903964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the bolt and 2 nuts.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    9. Install the 2 nuts.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      GTY919434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Connect the engine room main wire to the vehicle body with the nut.
      GTY919435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    11. Engage the guide and 2 claws to install the No. 1 terminal cap.
      GTY848011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  2. INSTALL FUEL TANK ASSEMBLY 

    Refer to INSTALLATION [02/2019 - ]

  3. INSTALL EXHAUST MANIFOLD 

    Refer to INSTALLATION [08/2020 - ]

  4. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 6

  5. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the vehicle body with the nut.

      Torque: 6.0 N.m (61 kgf/cm, 53 in.lbf) 

  6. INSTALL ENGINE SERVICE COVER CUSHION 
    1. Install the engine service cover cushion with the 2 nuts.
      GTY908346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

  7. INSTALL NO. 2 ENGINE SERVICE COVER CUSHION 
    1. Install the No. 2 engine service cover cushion with the 2 nuts.
      GTY908345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

  8. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR 
    1. GTY925920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the front No. 1 floor heat insulator with the 2 nuts.

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

  9. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR 
    1. Install the front lower No. 1 floor heat insulator with the nut and bolt.
      GTY903982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

    2. Install the clip.
  10. INSTALL FRONT NO. 2 FLOOR HEAT INSULATOR 
    1. Install the front No. 2 floor heat insulator with the 2 nuts.
      GTY920051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

    2. Install the clip.
  11. INSTALL FRONT CENTER FLOOR COVER 
    1. Install the front center floor cover with the 2 clips.
      GTY927320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 40 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 40 [12/2021 - ]

  13. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 41 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 41 [12/2021 - ]

  14. INSTALL ENGINE UNDER COVER HEAT INSULATOR 

    Refer to PROCEDURE - Step 42 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 42 [12/2021 - ]

  15. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 65 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 65 [12/2021 - ]

  16. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 66 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 66 [12/2021 - ]

  17. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH 

    Refer to PROCEDURE - Step 68 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 68 [12/2021 - ]

  18. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH 

    Refer to PROCEDURE - Step 67 [08/2020 - 12/2021] , or refer to PROCEDURE - Step 67 [12/2021 - ]

  19. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [11/2018 - ]

  20. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Engage the clamp.
      GTY942224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the HV under floor wire with the nut.
      GTY910945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.6 N.m (77 kgf/cm, 67 in.lbf) 

    3. Engage the clamp.
    4. Engage the 3 claws to install the No. 4 relay block cover.
      GTY910937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the shield ground to the HV battery.
    6. Connect the 2 HV battery junction block assembly connectors.
      NOTE:

      Make sure that the connectors are connected securely.

  21. INSTALL NO. 1 HV BATTERY COVER PANEL RH 

    Refer to PROCEDURE - Step 17

  22. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  23. INSTALL BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 5

  24. INSTALL NO. 2 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 6

  25. INSTALL REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 58 [08/2020 - 10/2023] , or refer to PROCEDURE - Step 58 [10/2023 - ]

  26. INSTALL NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 8

  27. INSTALL REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 58 [08/2020 - 10/2023] , or refer to PROCEDURE - Step 58 [10/2023 - ]

  28. INSTALL REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 13

  29. INSTALL BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 14

  30. CONNECT FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 13

  31. CONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.