NHTSA ID Number: 10214334
Manufacturer Communication Number: TSB002622
TSB/Document Date: 2022-06-21
Summary
TSB: Some 2019 ? 2021 model year RAV4 Hybrid
vehicles may exhibit a MIL ON condition with one or both of the following Diagnostic Trouble Codes (DTCs) stored: ?P0AA649 (Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure) ?P1C8049 (Hybrid/EV Battery Voltage System Isolation [Rear Motor Area] Internal Electronic Failure) The vehicle may also exhibit static or distortion when listening to AM radio. These conditions may be caused by corrosion on the high-voltage wire harness below the vehicle at connector Y6 at Motor Generator Rear (MGR) or dirt and debris inside the connector
T-SB-0026-22
March 23, 2022
MIL ON With DTCs P0AA649 and/or P1C8049 or AM
Radio Static/Distortion
Service
Category
Engine/Hybrid System
Section
Hybrid/Battery Control System
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2019 - 2021
RAV4 HV
VDS(s): BWRFV, D6RFV, DWRFV, E6RFV,
EWRFV, L6RFV, LWRFV, M6RFV, MWRFV,
R6RFV, RWRFV
Introduction
Some 2019 – 2021 model year RAV4 Hybrid vehicles may exhibit a MIL ON condition with one or
both of the following Diagnostic Trouble Codes (DTCs) stored:
P0AA649 (Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure)
P1C8049 (Hybrid/EV Battery Voltage System Isolation [Rear Motor Area] Internal
Electronic Failure)
The vehicle may also exhibit static or distortion when listening to AM radio. These conditions may
be caused by corrosion on the high-voltage wire harness below the vehicle at connector Y6 at
Motor Generator Rear (MGR) or dirt and debris inside the connector. Follow the Repair Procedure
in this bulletin to address these conditions.
Figure 1. Image of HV Floor Under Wire Pathway Through Vehicle
1
1
Area of Concern
© 2021 Toyota Motor Sales, USA
Page 1 of 8
T-SB-0026-22
March 23, 2022
Page 2 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Introduction (continued)
Figure 2.
1
2
1
Dirt, Corrosion, and Debris Build-up
2
Corrosion
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
BATTERY TYPE
PRODUCTION CHANGE EFFECTIVE VIN
NiMH
JTMDWRFV#MJ052960
JTMEWRFV#MJ052960
JTMRWRFV#MJ052960
JTMMWRFV#MJ052960
JTMLWRFV#MJ052960
Li-Ion
JTMD6RFV#MJ003713
JTME6RFV#MJ003713
JTMR6RFV#MJ003713
JTMM6RFV#MJ003713
JTML6RFV#MJ003713
NiMH
JTMDWRFV#MD095893
JTMEWRFV#MD095893
JTMRWRFV#MD095893
JTMMWRFV#MD095893
JTMLWRFV#MD095893
Takaoka
RAV4 HV
Nagakusa 301
© 2021 Toyota Motor Sales, USA
T-SB-0026-22
March 23, 2022
Page 3 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Production Change Information (continued)
MODEL
PLANT
Nagakusa 301
BATTERY TYPE
PRODUCTION CHANGE EFFECTIVE VIN
Li-Ion
JTMD6RFV#MD018624
JTME6RFV#MD018624
JTMR6RFV#MD018624
JTMM6RFV#MD018624
JTML6RFV#MD018624
NiMH
JTMDWRFV#MD558409
JTMEWRFV#MD558409
JTMRWRFV#MD558409
JTMMWRFV#MD558409
JTMLWRFV#MD558409
Li-Ion
JTMD6RFV#MD510362
JTME6RFV#MD510362
JTMR6RFV#MD510362
JTMM6RFV#MD510362
JTML6RFV#MD510362
NiMH
2T3DWRFV#MW107554
2T3EWRFV#MW107554
2T3BWRFV#MW107554
2T3RWRFV#MW107554
2T3MWRFV#MW107554
2T3LWRFV#MW107554
Li-Ion
2T3D6RFV#MW016091
2T3E6RFV#MW016091
2T3R6RFV#MW016091
2T3M6RFV#MW016091
2T3L6RFV#MW016091
NiMH
4T3DWRFV#MU012238
4T3EWRFV#MU012238
4T3RWRFV#MU012238
4T3MWRFV#MU012238
4T3LWRFV#MU012238
Li-Ion
4T3D6RFV#MU031367
4T3E6RFV#MU031367
4T3R6RFV#MU031367
4T3M6RFV#MU031367
4T3L6RFV#MU031367
Nagakusa 302
RAV4 HV
TMMC
TMMK
© 2021 Toyota Motor Sales, USA
T-SB-0026-22
March 23, 2022
Page 4 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Warranty Information
OP CODE
DESCRIPTION
TIME
EL9065
R & R HV Floor Under Wire
4.7
Combo A
R & R Cable, Motor, No. 2
4.2
OFP
T1
T2
821H1-XXXXX*
8A
73
*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 Basic Warranty. This warranty is in effect for
36 months or 36,000 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.
Parts Information
PART NUMBER
PRODUCTION REGION
PREVIOUS
NEW
NAP – North America
821H10R010
821H1-0R011
CBU – Japan
821H1-42020
821H1-42021
G1149-42010
© 2021 Toyota Motor Sales, USA
PART NAME
QTY
Wire, HV Floor Under
1
Cable, Motor, No. 2
1
T-SB-0026-22
March 23, 2022
Page 5 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Required Tools & Equipment
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVI*
PART NUMBER
QTY
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 16.30.011 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
01413-00072 (Medium)
Insulated Glove Set, Rubber With Leather Protectors*
01413-00073 (Large)
1
01413-00074 (Extra Large)
*Essential SST.
CAUTION
ALWAYS inspect the insulated gloves before use for cracks, ruptures, tears, pinholes, or damage.
Do NOT wear if damaged.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2021 Toyota Motor Sales, USA
T-SB-0026-22
March 23, 2022
Page 6 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Repair Procedure
1. Confirm the condition exists.
A. Using Techstream, run a Health Check and confirm one or both of the following DTCs
are present:
P0AA649 (Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure).
P1C8049 (Hybrid/EV Battery Voltage System Isolation [Rear Motor Area] Internal
Electronic Failure).
Are either or both DTCs listed above present or is there AM radio static/distortion?
YES — Continue to substep B.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
CAUTION
Orange wire harnesses and connectors indicate high-voltage circuits. To prevent
electric shock, always follow the procedure described in the repair manual to disable
the high-voltage system.
To prevent electric shock, wear insulated gloves when working on wire harnesses and
components of the high-voltage system.
B. Disconnect the Y6 connector at the MGR and inspect for corrosion, dirt, or debris.
Is dirt, debris, or corrosion present?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
© 2021 Toyota Motor Sales, USA
T-SB-0026-22
March 23, 2022
Page 7 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Repair Procedure (continued)
2. Check connector housing of the MGR.
Is the chamfer or a further inner part
corroded as shown?
YES — Continue to step 3.
NO — Go to step 4.
Figure 3.
2
1
1
Chamfer
2
3. Replace the Cable, Motor, No. 2.
A. Remove Cable, Motor, No. 2 rear traction motor.
Refer to TIS, applicable model and model year Repair Manual:
2019 / 2020 / 2021 RAV4 HV:
Drivetrain – Hybrid Transmission/Transaxle – “Q610 (Hybrid Transmission /
Transaxle): Rear Traction Motor: Removal”
NOTE
ONLY steps 1 – 17.
B. Install NEW Cable, Motor, No. 2 from rear traction motor.
Refer to TIS, applicable model and model year Repair Manual:
2019 / 2020 / 2021 RAV4 HV:
Drivetrain – Hybrid Transmission/Transaxle – “Q610 (Hybrid Transmission /
Transaxle): Rear Traction Motor: Installation”
NOTE
ONLY steps 4 – 18.
© 2021 Toyota Motor Sales, USA
T-SB-0026-22
March 23, 2022
Page 8 of 8
MIL ON With DTCs P0AA649 and/or P1C8049 or AM Radio Static/Distortion
Repair Procedure (continued)
4. Replace the HV Floor Under Wire.
A. Remove the HV Floor Under Wire.
Refer to TIS, applicable model and model year Repair Manual:
2019 / 2020 / 2021 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Frame Wire: Removal”
B. Install the HV Floor Under Wire.
Refer to TIS, applicable model and odel year Repair Manual:
2019 / 2020 / 2021 RAV4 HV:
Engine/Hybrid System – Hybrid/Battery Control System – “Hybrid / Battery Control:
Frame Wire: Installation”
NOTE
As shown in Figure 5, the HV Floor Under Wire may have a different appearance than the
original part, shown in Figure 4. This is a normal condition.
Figure 4. Original Part Installed
Figure 5. New Part Installed
5. Using Techstream, run a Health Check to verify DTCs P0AA649 and P1C8049
are no longer present.
6. Test-drive the vehicle to ensure the condition no longer exists and the vehicle exhibits
proper operation.
© 2021 Toyota Motor Sales, USA
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium lead positive grid, maximizes conductivity and...
- Robust envelope separator with puncture resistant back...
- Vent cap design that resists acid leakage
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium Lead positive grid, maximizes conductivity and...
- Robust Envelope Separator with puncture-resistant back...
- Vent cap design that resists acid leakage
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: TSB002622
Replacement Service Bulletin Number:
MFR Communication Date: 2022-03-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU c0ding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Pr0gramming): Allows for Ford, for Lincoln, and for Mazda ECU pr0gramming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- 39+ Services/Resets/Adaptations/Relearns/Calibrations: XTOOL D7S full system car scanner diagnostic tool tackles 99% of common car issues through its 36+ special functions, including Oil Reset, EPB, SAS, BMS, Throttle Reset, Injector C0ding, ABS Bleed, TPMS Reset, Power Balance, etc and also covers specific-vehicle functions like Crank Sensor Relearn, ABS Initialization, Cylinder Power Balance, Fuel Trim Reset, Idle Relearn etc. This car diagnostic scanner enhances efficiency, making repairs and maintenance hassle-free. Tip: DO NOT for All vehicles, please check compatibility first
- Cost-effective ECU C0ding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase
- OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.