Ternary Lithium Battery Pack for Toyota RAV4 Hybrid (Including PHEV) 2nd Generation (2023-2024)

Product Overview

This high-performance Ternary Lithium (LiNiCoMnO₂, NCM) battery pack is engineered exclusively for the 2nd Generation Toyota RAV4 Hybrid (2023–2024) (XA50/XA60), supporting both standard Hybrid (HEV) and Plug-in Hybrid (PHEV/Prime) variants. As a core upgrade over earlier Ni‑MH batteries, it utilizes advanced NCM ternary lithium cells with superior energy density, faster charging, and enhanced thermal stability. Seamlessly integrated with Toyota’s 4th‑Gen Hybrid Synergy Drive (HSD) system, this battery delivers stronger electric assist, extended EV range (for PHEV), improved regenerative braking efficiency, and better fuel economy. Designed as a direct OEM replacement, it ensures perfect fit, plug‑and‑play installation, and restored hybrid system performance for aging RAV4 Hybrid and Prime models.

2. Key Features

Dual Variant Compatibility: Fits all 2nd Gen Toyota RAV4 Hybrid (2023–2024) HEV and PHEV (Prime) trims (FWD & E‑Four AWD‑i).

Advanced Ternary Lithium (NCM) Technology: High‑energy‑density nickel‑cobalt‑manganese oxide cells for lighter weight and higher power vs. Ni‑MH.

HEV & PHEV Optimized: HEV version for efficient hybrid cycling; PHEV version for extended pure‑electric driving and external charging.

Superior Thermal Management: Liquid cooling (PHEV) / active air cooling (HEV) maintains stable performance across -30°C to 55°C.

OEM Perfect Fit: Matches original dimensions, mounting, connectors, and BMS protocols for 100% plug‑and‑play installation.

High Power Output: Supports strong electric motor assist and rapid energy recovery during regenerative braking.

Long Cycle Life: Robust cell design withstands thousands of charge‑discharge cycles with minimal capacity fade.

Comprehensive Safety: Built‑in overcharge, over‑discharge, over‑current, short‑circuit, and over‑temperature protection.

Improved Cold‑Weather Performance: Maintains high discharge efficiency in frigid conditions better than Ni‑MH.

Low Self‑Discharge: ≤2% per month, ideal for long‑term vehicle storage.

Quality & Reliability: Manufactured to Toyota OEM standards for consistent, long‑term durability.

3. Specifications

Hybrid (HEV) Version

Battery Type: Ternary Lithium (NCM) Hybrid Traction Battery

Fitment: Toyota RAV4 Hybrid 2nd Gen (2023–2024) HEV | FWD & E‑Four AWD

Nominal Voltage: 259V

Nominal Capacity: 6.5Ah / 1.6 kWh

Cell Configuration: Prismatic NCM ternary lithium cells

Cooling System: Active air cooling

Operating Voltage Range: 194V – 298V

Cycle Life: ≥3,500 cycles (80% DOD, capacity retention ≥80%)

Operating Temperature: -30°C to 55°C

Weight: ~32 kg (≈33% lighter than 1st‑gen Ni‑MH pack)

Protection: Overcharge, over‑discharge, over‑current, short‑circuit, over‑temperature

Compatibility: 4th‑Gen Toyota HSD, Original BMS

Plug-in Hybrid (PHEV / Prime) Version

Battery Type: Ternary Lithium (NCM) PHEV Traction Battery

Fitment: Toyota RAV4 Prime / PHEV 2nd Gen (2023–2024) | AWD‑i

Nominal Voltage: 355.2V

Total Capacity: 18.1 kWh

Configuration: 96 series‑connected NCM modules

Cooling System: Liquid cooling

EV Range (EPA/WLTP): Up to 40–46 miles (68–78 km)

Charging: 6.6 kW on‑board charger; 240V charge: 0–100% in ~4.5 hours

Operating Temperature: -20°C to 55°C

Weight: ~120 kg

Protection: Full BMS with multi‑layer safety protocols

Compatibility: 4th‑Gen Toyota HSD, PHEV charging system