Online Forum for the 2012 Rav4 EV

This just started happening: I plug the EVSE cable in, the lights slowly blink like it's charging normally, then after about 12 seconds both lights blink 19 times and charging prematurely stops with a "charging stopped by system malfunction" error in the dashboard.

Before bringing it in to the dealership, I was wondering if there is something I can try to fix this. This error occurs regardless of whether I plug in the original 120V cable or the aftermarket 240V cable.

UPDATE:

If you are experiencing this same issue with your Rav4 EV, then try steps 1-6 of the "Tony Test" first. This could save you anywhere between $850 and $3500+ if the dealership misdiagnoses the root cause and ends up replacing a component that didn't need replacing.

Unfortunately this is the classic symptom of a failed on-board charger. Toyota wants a pretty penny for a replacement, but that isn't an issue if you have valid extended warranty. Tony Williams / Quick Charge Power may be able to provide a lower cost repair or replacement if your warranty has expired. In any case, it would be good to confirm that this is the issue by having a dealer (or perhaps QCP) read the error code on the car's bus.

Good luck, and let us know how things turn out!

Thanks, I just dropped it off at Tustin Toyota...already dropped $160 to diagnose it. The charging assembly is $3500, so let's hope it's not that. I should know in about a day or so. This is my first time paying for servicing after 72k miles, but I suspect it won't be the last.

I'll update here when I know more.

P.S. Tony is an option, but I'd need to get car towed from OC to SD since it's only got 49 miles of range.

Documented/factual diagnostic results, for example, Tesla electric propulsion control systems fault codes (aka alert codes*) and the results of additional Checks?

Judging by the price, I assume that only Toyota systems were diagnosed...

* For example, code CHG_f028

http://alflash.com.ua/2019/to_rav4ev/_f028.png

or code CHG_f078
https://youtu.be/-TQCu5Tqm6c?t=9

UPDATE: Luckily Tustin Toyota still had an EV specialist on hand to do a proper diagnosis. Good news: the fault likely isn't with the onboard charging assembly ($3500 excluding labor). The not-so-good news: there is an intermittent electrical problem with the charging port, which needs to be replaced, and the total cost including labor is $850.

Ours is a 2012 we live in Huntington Beach and the RAV has 68K miles. We still get good range on a charge like 100 to 120. The car died on my wife fortunately I was able to figure out it was the speed sensor on the motor and bought one from Tony it fixed the problem. I'm hoping other things don't start going wrong

If your nearby I'd be happy to help out with any other problems you run into or maybe you can help us out if ours goes south. Or we go to Tony!

Steve

Awesome, thanks in advance, Steve! We're in Mission Viejo, so not too far. Rav4 EVs are rare and getting rarer, so we're blessed to have this forum.

Just wondering: did the EV tech note any fault codes or specific behavior on the Tesla side? I'm curious how he determined it was the charge port and not the charger, might help others with similar symptoms..

The EV specialist wasn't working that day, so everything I was told was conveyed to me by the service manager who read it off his notes. He didn't mention any specific codes (hopefully I'll know more once I get the paperwork/receipt), but he did say the EV specialist was 99% sure it was the charging port because in the rare cases when all the pins did make a proper connection, the battery was charging properly. It seems the pins inside the charging port started to malfunction through seven years of wear and tear. Another thought that entered my mind, though highly unlikely, is that the aftermarket 240V charger connector I bought was responsible for this since it's kind of a tight fit compared to the stock 120V connector.

Other than the issue with certain early Blink EVSE J1772 nozzles frying sockets, I don't recall anybody having an issue with the RAV4 EV's inlet connector . . . but lots & lots of us have had failed onboard chargers. That's why yours is an important data point, if replacing yours eliminates that error message in the long term.