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Mil On With DTC(S) P1C84-49 And/Or P3004-49 In Freezing Temperatures (T-SB-0085-23 REV1)

WARNING: This page is about the Highlander Hybrid LE, 2.5L Eng VIN A, which is a different variant/trim than selected.
Publication date: 2023-11-17
Reference number: T-SB-0085-23 REV1
Supersedes refnos: T-SB-0085-23

MIL ON WITH DTC(S) P1C84-49 AND/OR P3004-49 IN FREEZING TEMPERATURES

MIL ON WITH DTC(S) P1C84-49 AND/OR P3004-49 IN FREEZING TEMPERATURES

TECHNICAL SERVICE BULLETIN

Reference Number(s): T-SB-0085-23 Rev1, Date of Issue:  November 17, 2023
TOYOTA: 2019 - 2022 Avalon HV; 2018 - 2023 Camry HV; 2022 Corolla HV; 2023 Crown, Sequoia HV; 2020 - 2023 Highlander HV; 2021 - 2023 Mirai, Sienna HV, Venza HV; 2017 - 2022 Prius Prime; 2016 - 2022 Prius; 2019 - 2023 RAV4 HV; 2021 - 2022 RAV4 Prime; 2022 - 2023 Tundra HV
SERVICE CATEGORY: Vehicle Interior
SECTION: Meter/Gauge/Display
MARKET: USA and Mexico
COPYRIGHT: © 2023 Toyota, USA License Agreement TMS1002
Superceded Bulletin(s): T-SB-0085-23, Date of Issue:  November 01, 2023

APPLICABILITY

APPLICABILITY

YEAR(S) MODEL(S) ADDITIONAL INFORMATION
2019 - 2022 Avalon HV  
2018 - 2023 Camry HV  
2022 Corolla HV  
2023 Crown, Sequoia HV  
2020 - 2023 Highlander HV  
2021 - 2023 Mirai, Sienna HV, Venza HV  
2017 - 2022 Prius Prime  
2016 - 2022 Prius  
2019 - 2023 RAV4 HV  
2021 - 2022 RAV4 Prime  
2022 - 2023 Tundra HV  

REVISION NOTICE 

November 17, 2023 Rev1: 

Any previous printed versions of this bulletin should be discarded. 

INTRODUCTION

Some 2016 - 2023 model year Toyota vehicles may exhibit a hybrid system warning lamp occurring in below-freezing temperatures (below 32°F or 0°C). After performing a Health Check, one or both of the following Diagnostic Trouble Codes (DTCs) may be present:

Follow the Repair Procedure in this bulletin to address this condition.

PRODUCTION CHANGE INFORMATION

This bulletin applies to vehicles produced BEFORE  the Production Change Effective VINs shown below.

PRODUCTION CHANGE INFORMATION

MODEL PLANT DRIVETRAIN BATTERY TYPE PRODUCTION CHANGE EFFECTIVE VIN
Avalon HV TMMK 2WD Li-ion 4T1AA1AB#NU015644
4T1EA1AB#NU015935
4T1#A1AB#NU015937
Camry HV TMMK (line 1) 4T1#31AK#PU059520
TMMK (Line 2) 4T1#31AK#PU619648
TMMK 2WD Ni-MH 4T1B21HK#PU020276
Corolla HV Takaoka 2WD Li-ion JTDEAMDE8NJ040666
JTDBARDE2NJ040680
JTDBAMDE1NJ040690
Crown Tsutsumi AWD Ni-MH JTDAAAAF#P3002952
JTDAFAAF#P3001216
Highlander HV TMMI (Line 1) 2WD 5TD#ARAH#PS021955
AWD 5TD#BRCH#PS130283
TMMI (Line 2) 2WD 5TD#ARAH#PS527352
AWD 5TD#BRCH#PS593492
Mirai Motomachi 2WD Li-ion JTDAAAAA#PA310008
Prius Tsutsumi JTDKA#FU#N3167037
AWD Ni-MH JTDL9#FU#N3035266
Prius Prime 2WD Li-ion JTDKA#FP#N3208831
RAV4 HV TMMK AWD Ni-MH 4T3#WRFV#PU101497
Li-ion 4T3#6RFV#PU130419
TMMC Ni-MH 2T3#WRFV#PW169155
Takaoka JTMRWRFV6PJ056266
Li-ion JTMD6RFV4PJ026838
JTMB6RFV1PJ026836
JTME6RFV3PJ026625
JTM16RFV2PJ026842
TICO (Line 26) Ni-MH JTMRWRFV5PD573895
JTMLWRFV0PD573891
JTMMWRFV0PD573930
Li-ion JTMD6RFV1PD540659
JTMB6RFVXPD540635
JTME6RFV8PD540632
JTM16RFV0PD540638
TICO (Line 27) Ni-MH JTMRWRFV6PD176888
JTMLWRFV8PD177112
JTMMWRFV1PD176971
Li-ion JTMD6RFV3PD089458
JTMB6RFV9PD089343
JTM16RFV0PD089324
RAV4 Prime TICO JTMCB3FV2ND080784
JTMAB3FV6ND080620
JTMEB3FV3ND080625
JTMFB3FV0ND083258
JTMGB3FV9ND080654
JTMGB3FV1ND083273
Sequoia HV TMMTX 2WD Ni-MH 7SVAAAAA#PX002136
4WD 7SVAAABA#PX016087
Sienna HV TMMI 2WD 5TD#RKEC#PS164578
AWD 5TD#SKFC#PS092709
Tundra HV TMMTX 2WD 5TF#C5AB#PX002697
5TF#C5BC#PX001180
4WD 5TF#C5DB#PX034074
5TF#C5EC#PX003943
Venza HV Takaoka AWD Li-ion JTEAAAAH4PJ126924
JTEAAAAH5PJ126866
JTEAAAAH6PJ126861
JTEAAAAH5PJ127144
JTEAAAAH0PJ126905
JTEAAAAH1PJ126993

WARRANTY INFORMATION

For USA Market

WARRANTY INFORMATION

OP CODE DESCRIPTION MODEL TIME OFP T1 T2
EL2309 R & R Hybrid Vehicle Relay Assembly Avalon Hybrid 0.9 G92Z0-#####(1) 8A 02
Camry Hybrid 0.9
Corolla Hybrid 1.0
Mirai 3.1
Prius 1.5
Prius Prime 2.0
RAV4 Hybrid w/ 0.8
VDS #6RFV
RAV4 Hybrid w/ 1.0
VDS #WRFV
Venza Hybrid 0.8
(1) 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

WARRANTY INFORMATION

OP CODE DESCRIPTION MODEL TIME OFP T1 T2
EL2311 R & R Hybrid Vehicle Relay Assembly Crown w/VDS AAAAF 1.0 G3850-#####(1)
G3860-#####(1)
8A 02
Crown w/VDS AFAAF 1.1
Highlander Hybrid 1.0
RAV4 Prime 3.5
Sequoia Hybrid 2.5
Sienna Hybrid 1.4
Tundra Hybrid 1.4
(1) 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

For Mexico Market

WARRANTY INFORMATION

OP CODE DESCRIPTION MODEL TIME OFP T1 T2
EL2309 R & R Hybrid Vehicle Relay Assembly Avalon Hybrid 0.9 G92Z0-#####(1) 8A 02
Camry Hybrid 0.9
Corolla Hybrid 1.0
Mirai 3.1
Prius 1.5
Prius Prime 2.0
RAV4 Hybrid w/VDS #6RFV 0.8
RAV4 Hybrid w/VDS #WRFV 1.0
Venza Hybrid 0.8
EL2311 R & R Hybrid Vehicle Relay Assembly Crown w/VDS AAAAF 1.0 G3850-#####(1)
G3860-#####(1)
8A 02
Crown w/VDS AFAAF 1.1
Highlander Hybrid 1.0
RAV4 Prime 3.5
Sequoia Hybrid 2.5
Sienna Hybrid 1.4
Tundra Hybrid 1.4
(1) 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

PARTS INFORMATION

For USA and Mexico Markets

PARTS INFORMATION

PART NUMBER PART NAME QTY
G92Z0-33041 - G92Z0-47100 Block Assy, HV Battery Junction 1
G92Z0-33051 - G92Z0-47110 1
G3850-48010 Box Assy, Traction Battery Device, No. 1 1
G3860-42010 Box Assy, Traction Battery Device, No. 2 1
G92Z0-47050 Block Assy, HV Battery Junction 1

REQUIRED TOOLS & EQUIPMENT

REQUIRED TOOLS & EQUIPMENT

SPECIAL SERVICE TOOLS (SST) PART NUMBER QTY
Battery Diagnostic Tool(1) DCA-8000P T  1
Insulated Glove Set, Rubber With Leather Protectors(1) 01413-00072  (Medium)
01413-00073  (Large)
01413-00074  (Extra Large)
(1) 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 (USA) or 01-800-504-5330 (Mexico).
PARTS INFORMATION

REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY
Techstream ADVI(1) ADE TSADVUNIT 1
Techstream 2.0 TS2UNIT
Techstream Lite TSLITEPDLR01
Techstream Lite (Green Cable) TSLP2DLR01
(1) Essential SST.
NOTE:
  • Only ONE of the Techstream units listed above is required.
  • GTS+ software version 2023.03.002.02 or later is required.
  • Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787 (USA) or 01-55-50103041 (Mexico).
  • Use Techstream or an approved J2534 interface to perform flash reprogramming updates. Visit techinfo.toyota.com  for more information regarding J2534 reprogramming.

REPAIR PROCEDURE

  1. Confirm the condition exists.

    Does the vehicle exhibit a hybrid system warning lamp in below-freezing temperatures (below 32°F or 0°C) with DTC(s) P1C8449 and/or DTC P300449 present?

    • YES  - Continue to step 2.
    • NO  - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
  2. Is the VIN BEFORE the one listed in the Production Change Information table?
    • YES  - Continue to step 3.
    • NO  - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
  3. Refer to the appropriate Repair Manual to gain access to the HV battery junction block/traction battery device.

    Refer to TIS, applicable model and model year Repair Manual:

    • 2019 - 2020  Avalon HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2021/2022  Avalon HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2018 - 2020/2021 - 2023  Camry HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2018 - 2020/2021 - 2023  Camry HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2022  Corolla HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2022  Corolla HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2023  Crown:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for A25A-FXS): Removal"

    • 2023  Crown:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for T24A-FTS): Removal"

    • 2020 - 2023  Highlander HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV°Relay Assembly: Removal"

    • 2021/2022/2023  Mirai:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV°Relay Assembly: Removal"

    • 2016 - 2018/2019 - 2020/2021 - 2022  Prius:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2016 - 2018/2019 - 2020/2021 - 2022  Prius:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2017 - 2019/2020/2021 - 2022  Prius Prime:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Removal"

    • 2019 (11/2018 - 02/2019)  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2019 (02/2019 - 10/2019)  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2020 (10/2019 - 06/2020)  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2020 (06/2020 - 08/2020)  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2021  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2022  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2023  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Removal"

    • 2020 (06/2020 - 08/2020)  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2021  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2022  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2023  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Removal"

    • 2021/2022  RAV4 Prime:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Removal"

    • 2023  Sequoia HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Removal"

    • 2021 - 2023  Sienna HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Removal"

    • 2022 - 2023  Tundra HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Removal"

    • 2021 - 2022/2023  Venza HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Removal"

  4. Perform an inspection of the SMRB and SMRG internal relays.
    G16167629
    1. Are the relays labeled Panasonic?

      See Figure 2 for an example of a relay labeled Panasonic.

      • YES  - Inspect the relay date code for the countermeasure date and go to step 5.
      • NO  - Continue to substep B.
      G16167630
    2. Are the relays labeled Denso?

      See Figure 3 for an example of a relay labeled Denso.

      • YES  - Inspect the relay date code for the countermeasure date and continue to step 5.
      • NO  - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
      G16167631
  5. Were the relays produced BEFORE the countermeasure date listed in step  4?
    • YES  - Continue to step 6.
    • NO  - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
  6. Install the NEW HV battery junction block/traction battery device.

    Refer to TIS, applicable model and model year Repair Manual:

    • 2019 - 2020  Avalon HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Installation"

    • 2021 - 2022  Avalon HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Installation"

    • 2018 - 2023  Camry HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Installation"

    • 2018 - 2023  Camry HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Installation"

    • 2022  Corolla HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Installation"

    • 2022  Corolla HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Installation"

    • 2023  Crown:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for A25A-FXS): Installation"

    • 2023  Crown:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for T24A-FTS): Installation"

    • 2020 - 2023  Highlander HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV°Relay Assembly: Installation"

    • 2021 - 2023  Mirai:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV°Relay Assembly: Installation"

    • 2016 - 2018/2019 - 2022  Prius:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Installation"

    • 2016 - 2022  Prius:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Installation"

    • 2017 - 2019/2020/2021 - 2022  Prius Prime:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Installation"

    • 2019 - 2023  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Nickel Metal Hydride Battery): Installation"

    • 2020 - 2023  RAV4 HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly (for Lithium-ion Battery): Installation"

    • 2021 - 2022  RAV4 Prime:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Installation"

    • 2023  Sequoia HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Installation"

    • 2021 - 2023  Sienna HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Installation"

    • 2022 - 2023  Tundra HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Installation"

    • 2021 - 2023  Venza HV:

      Engine/Hybrid System - Hybrid/Battery Control System -  "Hybrid/Battery Control: HV Relay Assembly: Installation"

  7. Clear ANY DTCs and test-drive the vehicle to confirm the condition is no longer present.