2014 Rav4 EV Dead - Dealer says cost will be $13k - vehicle will be total loss

Hello,

I have a 2014 RAV4 EV that I bought in 2016 from a CarMax in 2016. I have absolutely loved this car which caused me to keep it longer than I had planned and it seems that I have reached for the sun and got burned on this one.

A few weeks ago, realized that the car was not charging after being plugged in. Basically what happens is you plug in the plug. It appears it is about to start charging, then a few clicks happens and then an error message on the dash comes up "Charging: Stopped by System Malfunction". The vehicle battery did have enough charge left for me to take it to the dealer.

I took it to the dealer and they told me it would be $900 to do the diagnostics and would take 3 weeks to a month. Waited about 3 weeks and they called me back and told me this:

When they initially tried to run the diagnostics on the ECU, it would not hold the diagnostic codes for them to be able to read. They had to do some type of bypass using an ethernet cable, but eventually were able to tell me that the error code they are getting is "F078". They tell me this means that the onboard charger is bad. Also the ECU needs replacement. Total parts and labor for it all will be about $13K.

$13K is about the resale value of the car, so it appears I have a heap of scrap metal at the dealer. Does anyone know anything else that I can do to try to get this thing running again? I'm somewhat mechanically inclined and for $13K can spend alot of time trying to fix this thing. Any help is greatly appreciated!

Sometimes you can fix the problem by replacing the fuses, sometimes by replacing the on-board charger.

Check out the following threads:

https://www.myrav4ev.com/forum/viewtopic.php?t=2537
https://www.myrav4ev.com/forum/viewtopic.php?t=2530

davewill said:

Sometimes you can fix the problem by replacing the fuses, sometimes by replacing the on-board charger.

Check out the following threads:

https://www.myrav4ev.com/forum/viewtopic.php?t=2537
https://www.myrav4ev.com/forum/viewtopic.php?t=2530

Click to expand...

Plus
https://photos.app.goo.gl/qPgzekFwXkuGFPc99
+
https://youtu.be/jMHu2x7RC_I

Can you trust / how reliable is their information about the presence of this code in your vehicle?

mihalakj said:

Hello,
...
I took it to the dealer and they told me it would be $900 to do the diagnostics and would take 3 weeks to a month. ...

Click to expand...

NOTE. Flat rate labor time

• for DIAGNOSTICS (RAV4 EV, model No. QEA38) of Alert code CHG_f078 (OPERATION NUMBER CHG078) is 0.1 hour
  for R&R Charger is 4.8 hour
  
  

Please, check your email box and PM.

Yikes, $900 is a bit absurd for diagnostics, and should not take 3 weeks!

As others have noted, the most common failure mode for the charger assembly is a blown internal fuse. If you are mechanically inclined, it can be replaced, however I would rate it a 4 out of 5 for difficulty for the average person. A somewhat easier option (and a subset of the work required to replace the fuse) is to remove the bad charger and install another one. The Tesla gen 1 OBC used in early Model S cars is the same charger, just with different firmware in the RAV4. A replacement OBC can be re-flashed in the vehicle if you acquire your own charger (eBay), or alternatively I have re-flashed and tested OBCs available, PM me for info.

I doubt there is anything wrong with your ECU, it is likely the dealership's unfamiliarity with the tools/diagnostics.

Removal and installation of the on-board charger accounts for more 95% of all costs when eliminating this malfunction, replacing the fuse takes less than 5% of the repair time (of all time spent).

I am in the midst of trying to replace the fuses and I am using this as my guide:

Plus
https://photos.app.goo.gl/qPgzekFwXkuGFPc99

Can anyone tell me what is going on in these two pics

https://photos.app.goo.gl/BjFaps7TPCzPV3339
https://photos.app.goo.gl/to9H89Kn2M35zRjY8

I actually got past those two pics and figured it out before anyone was able to post. But now I'm faced with trying to understand what I am supposed to do in this picture?

https://photos.app.goo.gl/wc9P6U6PqAKNmXy8A

I assume there is something to disconnect in this box, but I can't tell what it is. Anyone else know? Thanks!

mihalakj said:

I am in the midst of trying to replace the fuses and I am using this as my guide:
Plus https://photos.app.goo.gl/qPgzekFwXkuGFPc99

Can anyone tell me what is going on in these two pics
https://photos.app.goo.gl/BjFaps7TPCzPV3339
https://photos.app.goo.gl/to9H89Kn2M35zRjY8

Click to expand...

p.s. (as "a posteriori" ).
https://www.youtube.com/watch?v=u1mQVl0Migw

This is a ferrite choke on the AC input to the charger. There is nothing to disconnect electrically, just physically unclip the assembly.

mihalakj said:

I actually got past those two pics and figured it out before anyone was able to post. But now I'm faced with trying to understand what I am supposed to do in this picture?

https://photos.app.goo.gl/wc9P6U6PqAKNmXy8A

I assume there is something to disconnect in this box, but I can't tell what it is. Anyone else know? Thanks!

Click to expand...

Update: the charger has been removed and a fuse is bad. now the journey to put it all back toether begins

During the removal of the charger I lost alot of the blue coolant/liquid when hoses were disconnected. Does anyone know what type of coolant that is so I can replace it all once I am done putting it all back together? Also how much do I need?

The blue coolant used in both the power electronics and battery cooling loops is G48, available at your local auto parts stores and Amazon. I believe it is only sold in gallon containers, which should be more than enough to replace your lost coolant.

Thank you! I will get some. Is the pink fluid antifreeze or something else?

The pink coolant is for the cabin heater core. Normally it shouldn't require replacement or topping off.

I preserved most of it but lost a little. maybe a 1/2 cup. Should I add more?

mihalakj said:

I preserved most of it but lost a little. maybe a 1/2 cup. Should I add more?

Click to expand...

Probably not worth it, but see how the level in the reservoir looks after running the heater for a bit. Similar advice for the powertrain coolant: re-check the fluid level after a few days of driving and letting the air find its way out of the system.

RAV4EV has a standard procedure Coolant Air Purge:
,
https://youtu.be/JpTVJ-i6GCk

Final Update!

The car is fixed. It was a several-day operation to get the components in the trunk disassembled enough to remove the charger and replace the fuse which was the problem. I was able to put everything back together and then contact alflash to help me run diagnostics and purge the air bubbles from the car.

Without alflash, all hope would have been lost and this car would have been sold for scrap parts. Thanks to alflash, I am able to take this car to CarMax, sell it, and have a substantial downpayment for my next vehicle.

Thanks alflash!

For any other RAV4EV owners that have this same problem, give this a try. It is not easy, but it is definitely worth recovering the cost of the vehicle!!!

VICTORY!

Does anyone know if there is a standard procedure for the SLLC pink coolant or do I just fill it up, run the heater and keep filling it until it stabilizes?