MG

Moderator
Please see T-SB-0046-21

Applicability:

2021 Toyota RAV4 Prime

Introduction:
Some 2021 model year RAV4 Prime vehicles may exhibit one or both of the following conditions:
* An inoperative AC inverter causing an inoperative rear AC outlet and Diagnostic Trouble Code (DTC) P1C0F96 (AC Inverter Signal Line Component Internal Failure) without MIL ON or warning message.
* A “Hybrid Warning” message and DTC P1BF862 (Hybrid/EV Battery Charger Coupler Temperature Sensor “A”/“B” Signal Compare Failure) with MIL ON.

Use the Repair Procedure in this bulletin to address these conditions.

Warranty Information:
R & R Hybrid or EV Charger Assy and Install the EV Charger Seal

APPLICABLE WARRANTY:
* This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date.

* Warranty application is limited to occurrence of the specified condition described in this bulletin.

* 2021 model year RAV4 Prime Vehicles that are registered and normally operated in California, Arizona (2012 model year ONLY), Connecticut (starting with 2005 model year), Maine (starting with 2004 model year), Maryland (starting with 2011 model year), Massachusetts (starting with 2004 model year), New Hampshire (2005 – 2009 model year ONLY), New Jersey (starting with 2005 model year), New Mexico (2010 – 2011 model year ONLY), New York (beginning with 2004 model year with (Zero Emissions) ZE models ONLY; ALL models starting with 2016 model year), Oregon (starting with 2008 model year), Rhode Island (starting with 2005 model year), & Vermont (starting with 2004 model year) – Partial Zero Emission Vehicle (PZEV) Emission Warranty Coverage is in effect for 15 years or 150,000 miles, from the vehicle’s in-service date, whichever occurs first. (Please reference Warranty Policy Bulletin POL14-09 for additional information).

* Three additional states Delaware beginning with (2014 model year), Pennsylvania (beginning with 2008 model year), Washington (beginning with 2009 model year) have adopted the California Emission Warranty, however, in these states performance and long-term defect warranty coverage is 7 years or 70,000 miles, whichever occurs first.

Repair Procedure:
1. Confirm the vehicle exhibits one or more of the following conditions:
* An inoperative AC inverter causing an inoperative rear AC outlet AND DTC P1C0F96 without MIL ON or warning message.
* A “Hybrid Warning” message AND DTC P1BF862 with MIL ON.
Does the vehicle exhibit one or more of the conditions listed above?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.

2. Verify the vehicle is equipped with a 6.6 kW charger assembly. Refer to TIS, applicable model and model year Repair Manual:
Is the vehicle equipped with a 6.6 kW charger assembly?
YES — Continue to step 3.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.

3. Using Techstream, determine the temperature difference between the AC charging positive inlet temperature and AC charging negative inlet temperature.
Is the temperature difference greater than 5.4°F (3°C)?
YES — Continue to step 4.
NO — Go to step 6

4. Remove the electric vehicle charger assembly.

5. Install the NEW electric vehicle charger assembly.

6. Remove the rear bench seat

7. Install the electric vehicle charger seal.
A. Peel back the adhesive tape cover from the charger seal.
B. Align the charger seal with the corners of the parts label and allow the front left tab to pass under the wire harness
C. Firmly press down to add pressure on the adhesive tape to secure the seal to the top of the charger in the location shown.

8. Reinstall ALL connections.

9. Reinstall the rear bench seat.

10. Clear ALL DTCs, charge the vehicle, and run a Healthcheck using Techstream to confirm the conditions no longer exist and DTCs do NOT reappear
 
Top