TSB002622

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
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T-SB-0026-22
March 23, 2022
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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
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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
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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
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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
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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
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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
Corrosion
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
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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