Heavy Duty Battery Rav 4.1

[aiberdonian]

I've had a 096 72 AH Battery in my GXS for the past 2 years and when the 015 45 AH 'lawn mower' Battery in the EX went flat after only a week while I did some cleaning and painting on the undserside in preparation for winter conditions I decided it too had to have the same modification.

The 096 is 11" long x 7" wide x 7 1/2" high and required a piece of 5/8" thick plywood or board 9 3/4" long x 6 3/4" wide placed in the existing Battery tray to give it a flat base to sit on.

A piece of perforated non slip sponge rubber matting was then cut to 11" x 7" to keep it from sliding about as there is now no positive location for the base of the battery.

The terminals are at the bulkhead side so the leads need to be longer - I made up a new earth lead 10" long and extended the live lead by 4 1/2" so that the leads aren't being stretched.

The existing hold down clamp has still been used but the location lugs bolted to it need to be adjusted either by elongating existing holes or drilling new ones to fit the top profile of the battery and this depends on the make as some have a 'top hat' shape while others are more or less flat across the top.

The existing 6 mm hold down bolts are just long enough to get full thread in the nuts and the one at the bulkhead side is a bit of a fiddle to make sure the hooked end is properly located.

As I said I have had one in the GXS for 2 years and the battery has never moved in that time (25,000 mls.) but maybe some people with modified engines who indulge in a bit of drag racing might need a more positive method of location!!

[dave.m]

Good idea, can you add some photos to this thread ? its always helpfull for others

[aiberdonian]

Good idea, can you add some photos to this thread ? its always helpfull for others

See what I can do, but must admit to being a lot more at ease with a socket set and ball pein hammer than a digital camera and mouse.

[bothwell_buyer]

hahaha

well done!! a pic of the new Battery would be good - just get one developed and stick it on your screen! Or send it to dave.m and he is good with pics....being from Aberdeen, we all appreciate that the economic downturn must have affected you dreadfully!!

At the moment, I'm not driving following an op, but before, I had a problem with 2 warning lights....

1 is the brake warning which is the wire to the rear brake sensor having got damaged while wading thru water.

2 is the alternator/charging warning light. The alternator is charging ok, but the guys at the garage reckon the heat from the turbo has affected the smaller output from the alternator which feeds the warning circuit. I have a new/spare alternator and it'll be changed when the car goes in to get the rear bushes changed hopefully very soon......so.....

In the back I have a set of very long, very heavy jump leads and a large spare Battery wedged in behind the seats just in case the alternator gives up!! Not at all ideal, but just a short term measure. Looks as if I'll have number 2 RAV by the end of the month anyway, and with its new engine and original seats it'll be more comfortable to drive. When number 1 goes into get sorted, I'll mention to the guys about swapping the Battery.

Thinking of changing the petrol tank as well as the original is reaching end of life. Maybe a low profile foam filled tank inside which would allow the exhaust pipe to run higher up...

[Bodgit-fixit-run]

Thinking of changing the petrol tank as well as the original is reaching end of life. Maybe a low profile foam filled tank inside which would allow the exhaust pipe to run higher up...

Ok I have to ask. What is a foam filled tank and how does it work?

I've seen them mentioned a few times on the site Never heard of them before joining.

[Fujisan]

Thinking of changing the petrol tank as well as the original is reaching end of life. Maybe a low profile foam filled tank inside which would allow the exhaust pipe to run higher up...

Ok I have to ask. What is a foam filled tank and how does it work?

I've seen them mentioned a few times on the site Never heard of them before joining.

See the link.

[bothwell_buyer]

Here's a couple of links -

one for foam

and one for the tank This is just an illustration - as the RAV doesn't have an internal spare wheel, I'm looking at a flat tank for the inside behind the 2 front seats.

Funnily enough, my landrover has an internal fuel tank as its been modified for serious off-road.