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Toyota RAV4 Hybrid Owners Take Note Of This Important Defect Report

The Toyota RAV4 Hybrid from 2019 to 2020 is experiencing an unusual series of failures related to the high voltage wire harness.
Image of Toyota RAV4 Hybrid Component courtesy of Tom Smeal

The Toyota RAV4 Hybrid is one of America’s top-selling green crossovers. With sales passing 100,000 units in the past few years, it is more popular than many major brands’ mainstream crossovers. And it has been proven to be extremely reliable. However, there is one odd failure beginning to cause issues for owners.

Internal Toyota service notification T-TT-0630-20 alerts its dealer technicians that some 2019-2020 model year RAV4 HV vehicles may experience DTC codes P0AA649 / P1C8049. These codes indicate “Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure” or, “P1C8049-Hybrid/EV Battery Voltage System Isolation (Rear Motor Area) Internal Electronic Failure.” Toyota goes on to say that the root cause of the issue is a short in MGR connector due to corrosion. The alert was issued by Toyota on October 27, 2020.

If an owner experiences this problem, technicians are advised to “Raise the vehicle to visually inspect the high voltage wire harness that connects to the MGR. Unplug and check for corrosion or buildup of dirt and sediment in the connector.” They are then advised to “Confirm the cable corrosion or dirt build-up at the MGR connector and call TAS for further instruction. If it is a weekend or holiday, continue with diagnosis and repair. Please save all parts and/or details and contact TAS on the next available workday.”

Related Story: Dealer Won’t Honor Your Warranty? Here’s What To Do And Why You Should Not Give Up

Clearly, Toyota has identified a possible problem related to this portion of the RAV4 Hybrid’s powertrain. If your vehicle displays a check engine light and the technician identifies the codes listed above request a warranty repair. Hybrid components are warrantied by Toyota for 8 years/100,000 miles, whichever comes first. The parts listed in the technical alert are all part of the hybrid drive system. As you can tell simply from their names.

In the event that the dealer pushes back on covering the cost of repairs under warranty, try calling Toyota’s corporate customer support line for help. Let them know you are aware of the Internal Toyota service notification T-TT-0630-20 and that you know your hybrid components are warrantied for 8-years or 100K miles. In the event you do have to pay for any repairs or diagnostic fees, retain your receipt because it is likely a future recall or class action suit may end up with a reimbursement program.

If your Toyota RAV4 Hybrid has experienced this problem, please tell us about your experience in the comments below. Your notes may assist other owners.

Image of Toyota RAV4 Hybrid Component courtesy of Tom Smeal.

John Goreham is a long-time New England Motor Press Association member and recovering engineer. John's interest in EVs goes back to 1990 when he designed the thermal control system for an EV battery as part of an academic team. After earning his mechanical engineering degree, John completed a marketing program at Northeastern University and worked with automotive component manufacturers, in the semiconductor industry, and in biotech. In addition to Torque News, John's work has appeared in print in dozens of American news outlets and he provides reviews to many vehicle shopping sites. You can follow John on TikTok @ToknCars, on Twitter, and view his credentials at Linkedin

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Comments

Michel Paul Cote (not verified)    April 6, 2022 - 4:22PM

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It made the national newspaper in Montreal today.(lapresse+l. Over 300 failures in Quebec, and Toyota refuses to cover under the 8 year warranty. They claim it is not part of the drivetrain. Cost of repair is 7500$. Transport Canada is looking into the matter. Not a great customer service approach from Toyota. Had issues with the front seat not heating, no way to tow the car, and now this. After 8 Toyotas, it might be my last one.

Jim young (not verified)    April 15, 2022 - 5:47PM

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I have a 2019 toyota rav4 hybrid with 95000 km on it, got a hybrid malfunction warning, took it to Toyota dealer in Barrie Ontario, wire harness shows corrosion, dealer and Toyota say it is not covered by any warranty and with cost me $8000.00 to repair.

Margaret J Kaufman (not verified)    April 26, 2022 - 9:11PM

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Our 2019 RAV4 Hybrid had the corrosion of the wiring harness at 60,000 miles. Toyota stated that the part is not covered by warranty. We paid $4000 to have it repaired.

Liam Doherty (not verified)    May 8, 2022 - 9:52AM

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2020 Rav4 hybrid with 40,000kms. Car just stopped and gave me a "hybrid system malfunction. Visit your dealer." After 5 minutes the car would start, run in gas only. Got it to the dealer. They said don't drive it as it could go into 'limp mode' without warning, dropping me down to 15kmh on the highway in a heartbeat. Backorder of the part is at least a month. They have no idea. But it's under warranty for me.

Gord (not verified)    May 20, 2022 - 7:58AM

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My 2021 Rav4 hybrid has been sitting at the dealer for 3 weeks. They claim Toyota can not give them a delivery date on the wiring harness but acknowledge it will not be soon. At least one other hybrid sitting on the lot with the same issue.
Toyota paying for a rental.

Amy (not verified)    May 24, 2022 - 3:23PM

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Did they tell you not to drive it? Mine just said that it should be fine to drive until the part comes in. There are currently almost 300 of them backordered. I really need my car back but kind of worried about driving it.

Peggy Kaufman (not verified)    May 25, 2022 - 9:01AM

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I was told not to drive it. If the wiring harness is corroded, it seems like it would endanger the rest of the electrical system. Toyota did not assist me in any way as I waited a month for repairs.

Wayne Groves (not verified)    June 3, 2022 - 10:39AM

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2019 Rav 4 with 27000 km sitting on dealer's lot. Latest from Toyota is 3 months for wiring harness. Gets extended a month every time I call.

Kate (not verified)    June 8, 2022 - 1:29PM

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Got "hybrid malfunction" error on 2019 model at 34k. Took 1.5 weeks to get an appointment at VT Toyota dealership, told it was the harness corrosion issue, 3 weeks post identification and still waiting on a part with no updates. Was told by service tech it would be covered by warranty however won't believe it until I see it. Was also told not to drive it, as it could stop driving at any time. It took Toyota 1.5 weeks to find a rental, but they are covering the rental cost.

Jim Berrigan (not verified)    June 30, 2022 - 8:18PM

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How much is a new cable that doesn’t have the corrosive problem. I am Willing to buy the cable to prevent this meltdown of other electrical components. I have corrosion on the cable and Toyota won’t cover shit so if I New the cost of the cable I might have a chat with them.

John Pavel (not verified)    July 11, 2022 - 2:29PM

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I'm living this issue right now. Toyota agreed to supply the part at their cost, but I must pay the labor. Says the reason is rust and thats why its not fully covered. I live in Cleveland, it snows! I have my rav for 24 months...does that mean I can expect the same issue 24 months after is replaced?

Kris Rexroad (not verified)    July 21, 2022 - 7:43PM

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2019 rav 4 hybrid 40 000 miles cortisone on battery. 3800. Repai bill 2450 for the harness rest in labor

Carmel McColgan (not verified)    July 25, 2022 - 3:41PM

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I have the same problem on my 2019 RAV4 Limited Hybrid. Alert stated, “Malfunction in the Hybrid System” but the wiring harness is not covered under the hybrid warranty. It will cost me ~$5300 for repair. Car has 51k miles, less than 3 years old. And no idea when the part will come in.

Mary (not verified)    August 23, 2022 - 7:48PM

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August 2022: We received a warning message that our RAV4 hybrid system malfunctioned. We took it to our dealer. They contacted Toyota and Toyota covered the repair fully ($4,000) and the car was repaired quickly. A great response from Toyota.

Santoli Joseph (not verified)    September 25, 2022 - 4:26PM

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I just filed a US class action which extends Toyota & Lexus-wide: Isenberg v. Toyota DNJ. Defect for Subaru CrossTrek & Toyota Sienna.

Kevin Frank (not verified)    July 31, 2023 - 4:52PM

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I had a 2020 Rav 4 hybrid with a wiring harness failure that I got replaced for $4800 and then they said the new one ( which had a modification) was only going to be guaranteed for 1 year so I took the Rav and traded it in less the costs of repair taken off my trade in. I am now trying to get reimbursed through Toyota with no luck so far. I would like to be part of this class action law suit againt Toyota.

Santoli Joseph (not verified)    September 25, 2022 - 4:28PM

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I just filed a US class action which extends Toyota & Lexus-wide: Isenberg v. Toyota DNJ. Defect for Subaru CrossTrek & Toyota Sienna.

Kevin Frank (not verified)    October 13, 2022 - 2:34PM

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I have a 2020 Rav 4 hybrid 50K miles, it gave the same Hybrid system failure, the dealership stated that Is $4800 to repair and it is corroded because I live on a gravel road in MN and the powertrain warranty does not cover the hybrid wiring harness...

Kacie Speck (not verified)    October 17, 2022 - 12:00AM

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I have a 2019 RAV4 Hybrid with 24,500 miles. I received a message that my tire pressure sensor had an error - contact dealership. I took the car in and they said a drainage tube from the roof on the rear passenger side clogged and caused water damage (corrosion) to my wiring harness located near the front passenger side where your feet would be. Doesn’t make sense. They quoted me $8,200 to fix it.

I called Toyota Corporate and they said it was caused by outside influence so they wouldn’t be able to assist any further.

Remigijus (not verified)    February 6, 2023 - 1:26PM

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I have the same problem on my 2019 RAV4 Hybrid. at 6000km Alert stated, “Hybrid System mulfunction”/"PKSB Mulfunction" Spare part cost 2500eur . Dealer told that there is 99% that Toyota will cover it and I need to pay only for work. Waiting time 1month, And strongly recommended not to drive,due danger for electrical system mulfunction....So no car ....

Dan from Maine (not verified)    April 10, 2023 - 8:55AM

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My "Hybrid Malfunction" notice on my dash appeared. The service dept. at the dealership knew all about the issue after viewing it and diagnosing the issue. They told me not to drive it long distances. I had to rent a car on 2 occations while waiting for the parts to fix it. I was driving to work and back and around my town with no problems for a week. This morning the car would not start. The only thing I need is for my rental to be covered by Toyota. I am calling corporate recall department today.

Arlene (not verified)    April 28, 2023 - 2:34PM

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I am having an issue with the lift gate on my 2019 Toyota Rava 4 Hybrid. The gate will not close. At times none of the buttons will work and the lift gate needs to be closed manually but will resist being closed at the half way position. Have had it back to the dealer several times without resolution. Is this a common issue? What causes it?

Diana Tuttle (not verified)    May 4, 2023 - 10:40PM

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Had the same issue on my 2020 rav 4. It was a bent hinge which eas deemed a factory failure part and covered by Toyota. Call corporate office they r the one that helped my dealership wouldnt.