2015-2019 Toyota RAV4 Hybrid Installation Instructions






(Click on below images for larger
full size photo)

Time Required: Approx 1-1.5 hours

Tools Required:

Trim panel removal tool

8mm, 10mm, 12mm, 14mm sockets

Zip tie cutters or scissors

#0 flat heat screwdriver

#2 Phillips screwdriver

Recommended: volt meter

1) Remove the rear trunk floor cover, battery cooling fans cover, and rear seat backs

2) Remove seat bottoms and front lower kick panel to gain access to front of battery area. 

3) Remove seat bottom support frame to gain access to hybrid battery assembly

IMPORTANT: Remove orange battery safety switch.  Refer to this video for the proper way to install and remove the orange battery safety switch:  

https://youtu.be/YnhxDbkQ6uc?si=FOBfy9tOFlRHZxY7

4) Remove battery top cover from both sides of battery

5) Remove battery center brace to gain access to inside edge of modules

5) Remove battery center brace to gain access to inside edge of modules

6) Remove passenger side inner black battery buss bar cover

7) Remove driver side inner black battery buss bar cover

8) Lay the harness over the hybrid battery as shown in the photo at left

9) Connect black battery negative wire as shown in photo at left (click on image to enlarge)

10) Connect red battery positive wire as shown in photo at left (click on image to enlarge)

 

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11) OPTIONAL BUT RECOMMENDED:
We highly recommend taking a few extra minutes to clean the hybrid battery cooling fan intake screen. The fan intake often becomes clogged with debris. This contributes heavily to the hybrid battery overheating and premature failure.

12) Connect harness to driver side hybrid battery cooling fan by unplugging the connector shown at left and plugging the car harness fan box in line with the fan.

13) Connect harness to passenger hybrid battery cooling fan by unplugging the connector shown at left and plugging the car harness fan box inline with the fan. 

 

Route the connector end of the Prolong Car Harness into the trunk area near the spare tire.

14) Secure harness at this location and a few others others as needed using supplied cable ties.  This is to make sure harness cannot later be accidentally pulled out of the hybrid battery compartment.

15) IMPORTANT – Test the harness before finishing re-assembly of the vehicle. At all times, we recommend that you connect the charger to the car harness before plugging it into the wall and unplug it from the wall before disconnecting it from the car harness. 

To perform the initial function test: First, make sure all fingers and tools are clear of all wiring and hybrid battery components. Plug the Charger into the car harness. With the hybrid battery main disconnect still removed, plug the Charger into the wall. After a few seconds, it should read approx 295 volts on the meter and both the charger and hybrid battery cooling fans should be running. (2004-2009 Prius image shown at left for reference.)

Note in the image at left the hybrid battery main disconnect is not installed and the charger is displaying max voltage and no amperage.

16) To continue the test, power the system off, then carefully reconnect hybrid battery main disconnect.

Refer to this video for proper removal and installation of the HV battery disconnect switch:

https://youtu.be/YnhxDbkQ6uc?si=FOBfy9tOFlRHZxY7

17) Power the charger back on. You should see the charger voltage drops and equalizes with the voltage level of the battery pack. This should happen quickly. The voltage level should be stable and not fluctuating. All fans should still be running.

Note in the image at left the hybrid battery main disconnect is present and the charger is displaying battery voltage and amperage. (2004-2009 Prius image shown at left for reference.)

If anything is wrong, stop and contact us. If the fan is ‘pulsing’ (powering on and off) every few seconds, stop and contact us.

This completes the test. Unplug the Charger from the AC power source, remove the orange battery disconnect switch, and disconnect the Charger from the car harness

18) When not in use, the harness can be stored under the trunk carpet in the recessed area, similiar to what is shown in this reference photo

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19) Finish the installation by reassembling the vehicle in the reverse order of disassembly.

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