T-SB-0046-21.pdf - Misra,Prasun

Please enable JavaScript to view the full PDF

T-SB-0046-21 June 22, 2021 DTC P1C0F96 and/or P1BF862 With MIL ON Service Category Engine/Hybrid System Section Hybrid/Battery Control System Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2021 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. Production Change Information This bulletin applies to vehicles produced BEFORE the Production Change Effective VIN shown below. MODEL PLANT DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN RAV4 Prime Shokki – Nagakusa AWD JTM#B3FV#MD024467 © 2021 Toyota Motor Sales, USA Page 1 of 6 T-SB-0046-21 June 22, 2021 Page 2 of 6 DTC P1C0F96 and/or P1BF862 With MIL ON Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 R & R Hybrid or EV Charger Assy EL2037 1.5 and Install the EV Charger Seal G9099-420##* 8A 17 EL2038 Install the EV Charger Seal 1.4 *Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired by searching for the parts in the Electronic Parts Catalog using the VIN filter. 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. Parts Information PART NUMBER PART NAME QTY G9071-42030 Seal, EV Charger 1 G9099-42030* G9099-42031* G9099-42040* G9099-42041* Charger Assy, Electric Vehicle 1 G9099-42050* G9099-42051* G9099-42060* G9099-42061* *Determine the correct Electric Vehicle Charger Assembly part number for the affected vehicle. © 2021 Toyota Motor Sales, USA T-SB-0046-21 June 22, 2021 Page 3 of 6 DTC P1C0F96 and/or P1BF862 With MIL ON Required Tools & Equipment REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY Techstream ADVI* TSADVUNIT Techstream 2.0 TS2UNIT ADE 1 Techstream Lite TSLITEPDLR01 Techstream Lite (Green Cable) TSLP2DLR01 *Essential SST. NOTE  Only ONE of the Techstream units listed above is required.  Software version 16.00.021 or later is required.  Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787. 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:  2021 RAV4 Prime: Engine / Hybrid System – Hybrid / Battery Control – “Hybrid / Battery Control: Electric Vehicle Charger Assembly: Components” 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. © 2021 Toyota Motor Sales, USA T-SB-0046-21 June 22, 2021 Page 4 of 6 DTC P1C0F96 and/or P1BF862 With MIL ON Repair Procedure (continued) 3. Using Techstream, determine the temperature difference between the AC charging positive inlet temperature and AC charging negative inlet temperature. Refer to TIS, applicable model and model year Repair Manual:  2021 RAV4 Prime: Engine / Hybrid System – Hybrid / Battery Control – “Hybrid / Battery Control: Plug-in Charge Control System: Data List / Active Test” 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. Refer to TIS, applicable model and model year Repair Manual:  2021 RAV4 Prime: Engine / Hybrid System – Hybrid / Battery Control – “Hybrid / Battery Control: Electric Vehicle Charger Assembly: Removal” 5. Install the NEW electric vehicle charger assembly. NOTE  Complete steps 1 – 3 of the Repair Manual to install the NEW electric vehicle charger assembly.  Do NOT reinstall the rear bench seat until AFTER the charger seal has been installed. Refer to TIS, applicable model and model year Repair Manual:  2021 RAV4 Prime: Engine / Hybrid System – Hybrid / Battery Control – “Hybrid / Battery Control: Electric Vehicle Charger Assembly: Installation” AFTER the NEW electric vehicle charger assembly has been installed, go to step 7. 6. Remove the rear bench seat. NOTE Complete steps 1 – 26 of the Repair Manual to remove the rear bench seat. Refer to TIS, applicable model and model year Repair Manual:  2021 RAV4 Prime: Engine / Hybrid System – Hybrid / Battery Control – “Hybrid / Battery Control: Electric Vehicle Charger Assembly: Removal” © 2021 Toyota Motor Sales, USA T-SB-0046-21 June 22, 2021 Page 5 of 6 DTC P1C0F96 and/or P1BF862 With MIL ON Repair Procedure (continued) 7. Install the electric vehicle charger seal. Figure 1. Charger Assembly Schematic A. Peel back the adhesive tape cover from 3 the charger seal. 4 6 5 1 2 1 Rear of Vehicle 2 Driver’s Side 3 Charger Seal 4 Adhesive Tape 5 Parts Label 6 Electric Vehicle Charger Assembly B. Align the charger seal with the corners Figure 2. of the parts label and allow the front left tab to pass under the wire harness. NOTE 3  The charger seal should be installed with the electric vehicle charger 1 assembly installed in the vehicle.  Figures should be used 2 for reference ONLY. 1 Charger Seal 2 Parts Label 3 Electric Vehicle Charger Assembly © 2021 Toyota Motor Sales, USA T-SB-0046-21 June 22, 2021 Page 6 of 6 DTC P1C0F96 and/or P1BF862 With MIL ON Repair Procedure (continued) C. Firmly press down to add pressure on Figure 3. the adhesive tape to secure the seal to the top of the charger in the location shown. 2 3 NOTE  The charger seal should be installed with the electric vehicle charger 1 4 6 assembly installed in the vehicle. 1  Figures should be used for reference ONLY.  Ensure the front tab of the charger seal goes underneath the wire harness to 5 ensure proper fitting of the N60 connector into the charger assembly. 1 Front Tab 2 Wire Harness 3 Charger Seal 4 Firmly Press Here to Add Pressure 5 Parts Label 6 Electric Vehicle Charger Assembly 8. Reinstall ALL connections. 9. Reinstall the rear bench seat. NOTE Complete steps 4 – 23 of the Repair Manual to reinstall the rear bench seat. Refer to TIS, applicable model and model year Repair Manual:  2021 RAV4 Prime: Engine / Hybrid System – Hybrid / Battery Control – “Hybrid / Battery Control: Electric Vehicle Charger Assembly: Installation” 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. © 2021 Toyota Motor Sales, USA