23TA01 Engine Control Unit Software May Cause Stall – 2021 Toyota RAV4 Prime Plug-In Hybrid

SEOCONTENT-START

TOYOTA
Toyota Motor North America, Inc.
Vehicle Safety & Compliance
Liaison Office
Mail Stop: W4-2D
6565 Headquarters Drive
Plano, TX 75024
February 2, 2023
DEFECT INFORMATION REPORT
1. Vehicle Manufacturer Name:
Toyota Motor Corporation [“TMC”]
1, Toyota-cho, Toyota-city, Aichi-pref., 471-8571, Japan
Affiliated U.S. Sales Company:
Toyota Motor North America, Inc. [“TMNA”] 6565 Headquarters Drive, Plano, TX 75024
Manufacturer of Computer Assembly, Hybrid Vehicle Control:
DENSO CORPORATION
1-1, Showa-cho, Kariya-city, Aichi-pref., 448-8661, Japan
Phone: +81-566-25-5511
Country of Origin: Japan
2. Identification of Involved Vehicles and Affected Components:
Based on production records, we have determined the involved vehicle population as in the table below.
Make/Car Line
Model Year
Manufacturer
Production Period
Toyota / RAV4 Prime (Plug-In Hybrid)
2021
TMC
November 25, 2019
through
June 24, 2021
Applicability
Part Number
Part Name
Component Description
MY2021 Toyota RAV4 Prime (Plug-In Hybrid)
89980-42250
Computer Assembly, Hybrid Vehicle Control
Hybrid Vehicle Control ECU (HEV ECU)
Note: (1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S.
(2) This issue only affects MY 2021 RAV4 Prime (Plug-In Hybrid) vehicles equipped with a HEV ECU that contains the software logic described in this report. Other Toyota or Lexus vehicles sold in the U.S. are not equipped with those HEV ECUs.
3. Total Number of Vehicles Potentially Involved:
16,679
4. Percentage of Vehicles Estimated to Actually Contain the Defect:
100% of the involved plug-in hybrid vehicles contain the software logic described in this report. Whether this will actually lead to a hybrid system shut down after rapid accelerator pedal application while driving at higher speeds depends on the battery parameters and the vehicle operating mode at that time.
5. Description of Problem:
The subject plug-in hybrid vehicles contain software in the Hybrid Vehicle Control ECU (HEV ECU) to calculate the Hybrid battery (HV battery) output limits (maximum operating output) by monitoring battery voltage, state of charge (SOC), electrical load, and other parameters for battery protection. Due to certain characteristics of the software logic, the HV battery output may not be limited as required to protect the battery. If the accelerator pedal is rapidly pressed to further accelerate the vehicle after it has been continuously driven in “EV mode” in cold temperature and the HV battery voltage decreases, the voltage may drop rapidly below a specified threshold. If this occurs, the vehicle will display a warning message and the hybrid system will shut down, resulting in loss of motive power. If the vehicle loses motive power while being driven at higher speeds, there could be an increased risk of a crash.
6. Chronology of Principal Events:
March – August 2022
In early-March 2022, Toyota received a field report from Europe which indicated that, as the vehicle was driven on a freeway and the driver intended to accelerate, the vehicle suddenly had no additional throttle response. A dealer inspected the vehicle and found a DTC stored relating to HV battery voltage below threshold. The HV battery voltage was evaluated, but no issues were found. The HEV ECU was replaced. Because the HEV ECU was not recovered, no further analysis could be done.
In mid-March 2022, Toyota received a field report from Japan which described that the vehicle was being driven on an uphill road and then the system went to ready-off. Toyota also received another field report from Europe in April which stated the vehicle was accelerated while driving on a highway and then the vehicle lost motive power. Vehicle inspections were performed, and a DTC for HV battery voltage below threshold was stored. The HV batteries were inspected, but a decrease in HV battery voltage was not found. The HEV ECUs were replaced and sent to the supplier for investigation. However, other than the stored DTC, the supplier could not identify any abnormalities.
Toyota investigated the freeze frame data (FFD) collected from these vehicles and found the vehicles were driven in EV mode in cold temperatures. It was also noted that, when the DTC was stored, the system went to ready-off. The warning message was designed to display when the DTC was stored. Testing was done to attempt to replicate the incidents based on information from the customers and the FFD. A decrease of HV battery voltage was found to be more than expected under high load EV mode operation in cold temperatures when testing the vehicle on a chassis dynamometer; however, the warning messages and hybrid system ready-off could not be reproduced.
September 2022 – January 2023
Additional testing was conducted by rapidly pressing the accelerator pedal. As a result of the testing, when the vehicle was continuously driven in EV mode in cold temperatures and then the accelerator pedal was rapidly pressed to further accelerate the vehicle, the warning message and the system ready-off occurred. Analysis of these results indicated that the HV battery voltage decreased more than expected and the demand output limit information was sent to the HEV ECU for battery protection. However, the calculation of the output limit value by the HEV ECU was not following the output limit demand, and the output limit value was above the output limit demand. In this condition, if the accelerator pedal is pressed rapidly, the actual output is above the output limit demand, causing the voltage of battery cell to rapidly drop below the threshold, resulting in the warning message and system ready-off. Toyota concluded that the software logic in the subject vehicles created this condition.
Toyota collected vehicle data by using remote data retrieval from the market to assess the likelihood of future occurrences. Toyota concluded that voltage reduction due to hybrid battery deterioration over time could contribute to further occurrences.
January 27, 2023
Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign.
As of January 26, 2023, based on a diligent review of records, Toyota’s best engineering judgment is that there are no Toyota Field Technical Reports and 5 warranty claims that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report.
7. Description of Corrective Repair Action:
All known owners of the subject vehicles will be notified to take their vehicles to a Toyota dealer. For all involved vehicles, the dealers will update the Hybrid Vehicle Control ECU software at no cost.
Reimbursement Plan for pre-notification remedies
As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under the warranty.
8. Recall Schedule:
Notifications to owners of the affected vehicles will occur by April 3, 2023. A copy of the draft owner notification will be submitted as soon as it is available.
9. Distributor/Dealer Notification Schedule:
Notifications to distributors/dealers will be sent by February 2, 2023. Copies of dealer communications will be submitted as they are issued.
10. Manufacturer’s Campaign Number:
23TA01

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TOYOTA
This notice applies to your vehicle:
[VIN]
URGENT SAFETY RECALL
This is an important Safety Recall. The remedy will be performed FREE OF CHARGE to you.
IMPORTANT SAFETY RECALL (Remedy Notice)
2021 Model Year RAV4 Prime Vehicles
Vehicle May Lose Motive Power While Driving
NHTSA Recall No. [xxx-xxx]
Dear (customer’s First/Last name)
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Toyota has decided that a defect, which relates to motor vehicle safety, exists in 2021 model year RAV4 Prime vehicles.
You received this notice because our records, which are based primarily on state registration and title data, indicate that you are the current owner.
What is the condition?
The Hybrid Vehicle Control ECU (HEV-ECU) in the subject plug-in hybrid electric vehicles contains software that could cause the hybrid system to shut down after driving continuously in “EV Mode” in cold temperatures and then the accelerator pedal is rapidly pressed to further accelerate the vehicle. System shut down with loss of motive power at higher speeds can increase the risk of a crash,
What should you do?
Please contact any authorized Toyota dealer to schedule an appointment to have the remedy performed as soon as possible. Your local Toyota dealer will be more than happy to answer any of your questions.
Until the remedy has been performed, avoid driving in “EV Mode.
✓ To find a dealer near you, visit www.toyota.com/dealers.
✓ For more information on this and other Safety Recalls, including Frequently Asked Questions, visit www.toyota.com/recall. Input your full 17-digit Vehicle Identification Number (VIN) noted above to review information specific to your vehicle.
✓ If you require further assistance, you may contact the Toyota Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.
What will Toyota do?
Any authorized Toyota dealer will update the HEV-ECU FREE OF CHARGE to you.
This is an important Safety Recall
The remedy will take approximately 1 hour. However, depending on the dealer’s work schedule, it may be necessary to make your vehicle available for a longer period of time.
• To reduce the chance of the condition occurring, please have the recall remedy performed as soon as possible and avoid driving in “EV Mode” until the remedy has been performed.
What if you live in California and do not have this Safety Recall Campaign performed?
The state of California requires the completion of Safety Recalls / Service Campaigns on emission related parts prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the completion of this FREE Safety Recall Campaign the California Air Resources Board (CARB) will not allow your vehicle to be registered. State of California Regulations require Toyota to provide the Department of Motor Vehicles with a record of all vehicles that have not had the Safety Recall Campaign completed.
Your Toyota dealer will provide you with a Vehicle Emissions Recall Proof of Correction Form after the campaign has been completed. Please ensure you retain this form, because the DMV may require that you supply proof that the campaign has been completed during your vehicle registration renewal process.
What if you are not the owner or operator of this vehicle?
If you are a vehicle lessor, Federal Law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
If you know the current owner or operator, please forward this letter to them.
If you would like to update your vehicle ownership or contact information, please visit https://www.toyota.com/owners.
If you believe that the dealer or Toyota has failed or is unable to remedy the defect within a reasonable time or without charge, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153), or go to http://www.safercar.gov.
We have sent this notice in the interest of your continued satisfaction with our products. We sincerely regret any inconvenience this condition may have caused you.
Thank you for driving a Toyota.
Sincerely,
Toyota Motor Sales, USA

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Toyota Motor Sales, USA, Inc.
6565 Headquarters Drive
Plano, TX 75024
(469)292-4000
Original Publication Date: February 1, 2023
To:
All Toyota Dealer Principals, General Managers, Service Managers, and Parts Managers SAFETY RECALL 23TA01 (Remedy Notice)
2021 Model Year RAV4 Prime Vehicle May Lose Motive Power While Driving
Model / Years
Production Period
Approximate Total Vehicles
Approximate Stop Sale Dealer Inventory
2021 Model Year
RAV4 Prime
Late November 2019 –
Late June 2021
16,680
0
On February 2, 2023, Toyota filed a Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on 2021 model year RAV4 Prime vehicles. Condition The Hybrid Vehicle Control ECU (HEV-ECU) in the subject plug-in hybrid electric vehicles contains software that could cause the hybrid system to shut down after driving continuously in “EV Mode” in cold temperatures and then the accelerator pedal is rapidly pressed to further accelerate the vehicle. System shutdown with the loss of motive power at higher speeds can increase the risk of a crash. Remedy Any authorized Toyota dealer will update the software in the HEV-ECU FREE OF CHARGE. Covered Vehicles There are approximately 16,680 vehicles covered by this Safety Recall. No vehicles involved in this Safety Recall were distributed to Puerto Rico. Owner Letter Mailing Date Toyota will notify owners starting in late-February 2023. A sample of the owner notification letter has been included for your reference. Toyota makes significant effort to obtain current customer name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety Recall announcement, it is the dealership’s responsibility to forward the owner letter to the customer who purchased the vehicle. Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS. © 2020 Toyota Motor Sales, USA
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Dealer Inventory Procedures
New Vehicles in Dealership Inventory – Reminder
Toyota has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer’s obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory:
Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety. Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.
Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy.
NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.
Pre-Owned Vehicles in Dealer Inventory
To ensure customer satisfaction, Toyota requests that dealers complete this Safety Recall on any used vehicles currently in dealer inventory that are covered by this Safety Recall prior to customer delivery. However, if the campaign cannot be completed (for example, due to remedy parts availability), delivery of a covered vehicle is acceptable if disclosed to the customer that the vehicle is involved in a Safety Recall.
Toyota expects dealers to use the attached Customer Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Toyota and the dealer may use this information to contact the customer when the remedy becomes available.
Keep the completed form on file at the dealership and send a copy to quality_compliance@toyota.com. In the subject line of the email state “Disclosure Form 23TA01” and include the VIN.
NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (Non SET and GST dealers: https://dealerdaily.toyota.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.
Toyota Certified Used Vehicle (TCUV)
The TCUV policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a TCUV until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.
Toyota Rent-A-Car (TRAC) & Service Loaners
Toyota requests that dealers remove all TRAC and Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.
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© 2020 Toyota Motor Sales, USA
Customer Handling and Remedy Procedures
Customer Contacts
Customers who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.
Customers with additional questions or concerns are asked to please contact the Toyota Brand Engagement Center (1-888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.
Head Unit Notifications
Head unit notifications are electronic messages that are displayed in the vehicle’s audio system screen. Customers who receive head unit notification regarding this Safety Recall are requested to schedule an appointment with their authorized dealer to have this Safety Recall completed.
When these messages are received by the vehicle’s Data Communication Module, the head unit will display a pop-up prompt stating that the vehicle has a new Safety Recall. The prompt will contain options to ‘Snooze’ or to ‘View’ the message. If a customer chooses ‘Snooze’, the message will continue to reappear every 20 minutes until the customer chooses ‘View’. If a customer views and then closes the message, the message will be available in the Notification App if the customer chooses to review it again. If the vehicle’s completion status remains incomplete for a period of 90 days from the message being viewed, the head unit may display a renotification pop-up prompt as an additional reminder to the customer to have this Safety Recall completed.
The message will completely clear from the vehicle once the following conditions are met: The Safety Recall is completed, the dealer has filed a claim, and the claim is approved by Toyota. Then the message will be cleared at the next clearing cycle, which currently happens daily.
Owners who receive a head unit notification after having this Safety Recall completed can be advised to ignore the message. Owners with additional concerns can be directed to the Toyota Brand Engagement Center (1-888-270-9371) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.
Salvage Title Vehicles
Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.
For complete details on this policy, refer to Toyota Warranty Policy 4.17, “What Is Not Covered by The Toyota New Vehicle Limited Warranty”.
Media Contacts
It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Aaron Fowles (469) 292-1097 in Toyota Corporate Communications. Please do not provide this number to customers. Please provide this contact only to media.
Technician Training Requirements
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing this repair are required to successfully complete the most current version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure that all vehicles have the repair performed correctly; technicians performing this recall repair are required to successfully complete the following course:
• T623 – Electrical Circuit Diagnosis
Always check which technicians can perform the repair by logging on to https://www.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the above certification level or greater to perform this repair. Carefully review your resources, the technician skill level, and ability before assigning technicians to this repair. It is important to consider technician days off and vacation schedules to ensure there are properly trained technicians
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© 2023 Toyota Motor Sales, USA
available to perform this repair at all times.
Remedy Procedures
Refer to TIS for Technical Instructions on repair. Conduct all non-completed Safety Recalls and Service Campaigns on the vehicle during the time of appointment.
Repair Quality Confirmation
The repair quality of covered vehicles is extremely important to Toyota. To help ensure that all vehicles have the repair performed correctly, please designate at least one associate (someone other than the individual who performed the repair) to verify the repair quality of every vehicle prior to customer delivery.
Vehicles Emission Recall Proof of Correction Form (California only)
As this Safety Recall includes emission related parts, California dealers are requested to fill out the Vehicle Emissions Recall – Proof of Correction form after repairs have been completed. The vehicle owner may require this form for vehicle registration renewal. It is important to note that the forms are an official state document and blank forms must be secured to prevent misuse. Booklets can be ordered from the MDC (material number 00410-92007).
Please complete the form and provide it to the owner. The first non-completed VINs will be submitted to the California state DMV by early August 2023. If the vehicle owner’s warranty claim will not be processed and paid prior to this date, please be sure to complete a form and provide it to a California owner.
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© 2020 Toyota Motor Sales, USA
Warranty Reimbursement Procedures
Warranty Reimbursement Procedure
Op Code
Description
Flat Rate Hours
23TA01R1
Reflash HEV Battery ECU
0.8
•The flat rate times include 0.1 hours for administrative cost per unit for the dealership.•In the rare case that HEV-ECU contains the latest calibration ID (no software update needed), use opcode 23TA01R1.
Claim Filing Accuracy and Correction Requests
It is the dealer’s responsibility to file claims correctly for this Safety Recall. This claim filing information is used by Toyota for various government reporting activities; therefore, claim filing accuracy is crucial. If it has been identified that a claim has been filed using an incorrect Op Code or a claim has been filed for an incorrect VIN, refer to Warranty Procedure Bulletin PRO17-03 to correct the claim.
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© 2023 Toyota Motor Sales, USA
Campaign Designation / Phase Decoder
19
19 = 2019
20 = 2020
21 = 2021
22 = 2022
23 = 2023
Etc…
Year Campaign
is Launched
23TA01
T
T = Toyota
L = Lexus
Vehicle Make
A
A = Safety Recall Remedy
B = Safety Recall Interim
C = Special Service Campaign
D = Limited Service Campaign
E = Customer Support Program
F = Emissions Recall
(May use other characters in unique cases)
Field Action Category and Phase
01
01 = 1st Field Action of the year
02 = 2nd Field Action of the year
03 = 3rd Field Action of the year
(The sequence is unique for each Field
Action category)
(May use other characters in unique
cases)
Field Action Sequence
Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021
Please review this entire package with your Service and Parts staff to familiarize them with the proper step-by-step
procedures required to implement this Safety Recall.
Thank you for your cooperation.
TOYOTA MOTOR SALES, U.S.A., INC.
FAQ Page 1 of 2
© 2023 Toyota Motor Sales, USA
SAFETY RECALL 23TA01 (Remedy Notice)
2021 Model Year RAV4 Prime
Vehicle May Lose Motive Power While Driving
Frequently Asked Questions
Original Publication Date: February 1, 2023
Q1: What is the condition?
A1: The Hybrid Vehicle Control ECU (HEV-ECU) in the subject plug-in hybrid electric vehicles contains software that could cause the hybrid system to shut down after continuously driving in “EV Mode” in cold temperatures and then the accelerator pedal is rapidly pressed to further accelerate the vehicle. System shut down with loss of motive power at higher speeds can increase the risk of a crash.
Q1a: What are the specific circumstances under which this condition could occur?
A1a: Driving continuously in “EV mode” in cold temperatures and then rapidly depressing the accelerator pedal could cause this condition to occur.
Q1b: Are there any symptoms/warnings before the condition can occur?
A1b: No. There are no symptoms or warnings before system shut down with loss of motive power occurs. When shut down occurs, the vehicle will display a warning message.
Q1c: What should you do if this occurs?
A1c: If the system shut down occurs, the power steering and braking will still be operable. When motive power is lost, try to direct the vehicle to a safe location while coasting. Once stopped, place the vehicle in ”Park,” turn off the ignition, then restart the vehicle with the push button start. Turning the vehicle off and on will reset the vehicle and you will be able to continue to drive. Avoid driving the vehicle in EV mode if possible.
Q1d: How can I prevent this condition from occurring?
A1d: Until the remedy is performed, avoid driving the vehicle in “EV Mode”
Q2: What is Toyota going to do?
A2: Toyota will send an owner notification starting in late-February 2023, advising owners to make an appointment with their authorized Toyota dealer to have their HEV ECU updated FREE OF CHARGE.
NOTE (Customers who live in the state of California)
The state of California requires the completion of Safety Recalls / Service Campaigns on emission related parts prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the completion of this FREE Safety Recall, the California Air Resources Board (CARB) will not allow your vehicle to be registered. State of California Regulations require Toyota to provide the Department of Motor Vehicles with a record of all vehicles that have not had the Safety Recall completed.
Your Toyota dealer will provide you with a Vehicle Emissions Recall Proof of Correction Form after the campaign has been completed. Please ensure you retain this form, because the DMV may require that you supply proof that the campaign has been completed during your vehicle registration renewal process.
FAQ Page 2 of 2
© 2023 Toyota Motor Sales, USA
Q3: Which and how many vehicles are covered by this Safety Recall?
A3: There are approximately 16,680 vehicles covered by this Safety Recall.
Model Name
Model Year
Production Period
RAV4 Prime
2021
November 2019 – June 2021
Q4: How long will the repair take?
A4: The repair takes approximately 1 hour. However, depending upon the dealer’s work schedule, it may be necessary to make the vehicle available for a longer period of time.
Q5: How does Toyota obtain my mailing information?
A5: Toyota uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.
Q6: What if I have additional questions or concerns?
A6: If you have additional questions or concerns, please contact the Toyota Brand Engagement Center at 1-888-270-9371 Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.
© 2023 Toyota Motor Sales, USA – Version 3a
•• PROTECTED 関係者外秘
TOYOTA
Toyota Motor Sales, USA, Inc.
6565 Headquarters Drive
Plano, TX 75024
(469) 292-4000
CUSTOMER CONTACT & VEHICLE DISCLOSURE FORM
This form is not applicable for new vehicles in dealership inventory and TCUV units.
This vehicle is involved in a Safety Recall. At this time, remedy parts are not available and the remedy has NOT been performed. I understand that the vehicle will need to be returned to an authorized Toyota dealer to have the remedy performed at NO CHARGE when the remedy is available.
Customer Signature
Toyota recommends that you register with the Toyota Owners Community at http://www.toyota.com/owners/ and regularly check recall applicability using www.toyota.com/recall or www.safercar.gov. You will need to input your 17-digit Vehicle Identification Number (VIN).
Model
Model Year
Customer Information
Customer Name
Customer Email
Customer Address
Home Phone #
Mobile Phone #
Date
Please provide this information so that Toyota or your dealer can notify you when the remedy becomes available. This information will only be used for campaign communications. If you’d like to update your preferred contact information in the future, visit www.toyota.com/ownersupdate or contact us at 1-888-270-9371.
Dealer Information
Dealer Name/Address
Dealer Code
Dealer Phone Number
Dealer Staff Name
Dealer Staff Signature
VIN
Campaign Code

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-041
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Toyota Motor Engineering & Manufacturing FEB 02, 2023 NHTSA Recall No. : 23V-041 Manufacturer Recall No. : 23TA01
Manufacturer Information :
Manufacturer Name : Toyota Motor Engineering &
Manufacturing
Address : 6565 Headquarters Drive Plano TX 75024
Company phone : 1-800-331-4331
Population :
Number of potentially involved : 16,679 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2021-2021 Toyota RAV4 Prime Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : (1) Although the involved vehicles are within the above production period range, not all vehicles in this range were sold in the U.S. (2) This issue only affects MY 2021 RAV4 Prime (Plug-In Hybrid) vehicles equipped with a HEV ECU that contains the software logic described in this report. Other Toyota or Lexus vehicles sold in the U.S. are not equipped with those HEV ECUs. 100% of the involved plug-in hybrid vehicles contain the software logic described in this report. Whether this will actually lead to a hybrid system shut down after rapid accelerator pedal application while driving at higher speeds depends on the battery parameters and the vehicle operating mode at that time.
Production Dates : NOV 25, 2019 – JUN 24, 2021
VIN Range 1 : Begin : NR End : NR ntial Part 573 Safety Recall Report 23V-041 Page 2 Description of Defect :
Description of the Defect : The subject plug-in hybrid vehicles contain software in the Hybrid Vehicle Control ECU (HEV ECU) to calculate the Hybrid battery (HV battery) output limits (maximum operating output) by monitoring battery voltage, state of charge (SOC), electrical load, and other parameters for battery protection. Due to certain characteristics of the software logic, the HV battery output may not be limited as required to protect the battery. If the accelerator pedal is rapidly pressed to further accelerate the vehicle after it has been continuously driven in “EV mode” in cold temperature and the HV battery voltage decreases, the voltage may drop rapidly below a specified threshold. If this occurs, the vehicle will display a warning message and the hybrid system will shut down, resulting in loss of motive power. If the vehicle loses motive power while being driven at higher speeds, there could be an increased risk of a crash.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If this occurs, the vehicle will display a warning message and the hybrid
system will shut down, resulting in loss of motive power. If the vehicle loses motive power while being driven at higher speeds, there could be an increased risk of a crash.
Description of the Cause : NR Identification of Any Warning NR
that can Occur : Involved Components : Component Name 1 : Computer Assembly, Hybrid Vehicle Control Component Description : Hybrid Vehicle Control ECU (HEV ECU) Component Part Number : 89980-42250 Supplier Identification : Component Manufacturer
Name : DENSO CORPORATION
Address : 1-1, Showa-cho
Kariya-city, Aichi-pref Foreign States 448-8661 Country : Japan The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-041
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Chronology :
Please see the attached Part 573 Defect Information Report for the full chronology.
Description of Remedy :
Description of Remedy Program : All known owners of the subject vehicles will be notified to take their
vehicles to a Toyota dealer. For all involved vehicles, the dealers will update the Hybrid Vehicle Control ECU software at no cost. As the owner notification letters will be mailed out well within the active period of the Toyota New Vehicle Limited Warranty (“Warranty”), all involved vehicle owners for this recall would have been provided a repair at no cost under the warranty. How Remedy Component Differs NR from Recalled Component :
Identify How/When Recall Condition NR was Corrected in Production : Recall Schedule :
Description of Recall Schedule : Notifications to owners of the affected vehicles will occur by April 3,
2023. A copy of the draft owner notification will be submitted as soon as it is available. Notifications to distributors/dealers will be sent by February 2, 2023. Copies of dealer communications will be submitted as they are issued.
Planned Dealer Notification Date : FEB 02, 2023 – FEB 02, 2023
Planned Owner Notification Date : FEB 27, 2023 – APR 03, 2023
* NR – Not Reported

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