Charging: Stopped by System Malfunction

[Improve_RAV4EV]

Gentleman, this is what I got so far:
- HV cables on the passenger side of the OBC are NOT connected, as asavage suggested;
- Orange HV connector under the seat is put back in place firmly;
- 12V Battery is connected back;
- 61.2 Ohm is observed between pins 6 & 14 at Tesla DLC3 #2 port in the back;
- Vehicle turned ON;
- Was able to set it to "N" (pressing the "P" button for a while does NOT release the brakes), (was able to select "N" without HV plug in place, just 12V connected);
- Refuses to go into "D" or "R" (HV & AC disconnected at OBC);
- At first, no errors at dash, just lit warning symbols;
- Error came back after connecting the 240V wall outlet;
- Installed & run the V1.1.46 SW with following results. Your deciphering/comments/recommendations would be highly appreciated:

 

[alflash]

1. This RAV4EV Tesla system need reflash* (https://static.nhtsa.gov/odi/rcl/2015/RCMN-15V143-4464.pdf)

as show in https://www.myrav4ev.com/threads/problematic-rav4ev-without-teslas-codes.2694/#post-32689

2.The HVIL (High Voltage Inter Lock) fault code is probably a consequence of an assembly error after repair. And you can easily deal with it too.

3.The SOH* value of HV Battery is of concern...

* https://alflash.com.ua/2019/to_rav4ev/1392data.jpg

 

[asavage]

- HV cables on the passenger side of the OBC are NOT connected, as asavage suggested;

I don't recall this, but stored codes could be read without activating the HV side; however, the Gateway doesn't like to store codes

- 61.2 Ohm is observed between pins 6 & 14 at Tesla DLC3 #2 port in the back;

I haven't heard of anyone checking that before . . . but, for this vintage of CAN bus, ~60Ω is correct.

- Was able to set it to "N" (pressing the "P" button for a while does NOT release the brakes) . . .

???
This isn't a Tesla car, there are no electrically-applied parking brakes. It's a typical drum-brake-inside-rotor Toyota design. Same as most Toyotas of the period. Heck, it's the same as my Sienna.

- Refuses to go into "D" or "R" (HV & AC disconnected at OBC);

- Error came back after connecting the 240V wall outlet

The HVIL error BMS_f008 will prevent the BMS from closing the HV contactors, so you won't get the HV bus activated. Aside from reading stored codes, even a simulated charging session can't be done without the charger completely connected (except, perhaps, the coolant loop. The OBC won't generate enough heat fast enough to do any harm, unless you try to pull 40A for minutes. I expect you can run a cold OBC without any coolant flow for a minute or two at 12A).

With an HVIL error, you don't get HV and you can't complete a charge test session, so find the cause of the HVIL problem first. If the HV Service Disconnect (under passenger seat) is fully seated, it's almost certainly one of these:

1) The yellow (with black tape) HVIL loopback wire on the pass. side of the OBC:



From Tesla GEN1 OBC Wiki:



2) The translucent plastic cover on the HV terminals on the DC-DC (the cover must be in place, even if the wires underneath aren't), or one of the HV KET connectors isn't fully plugged in on the DC-DC (Cabin Heater, A/C Compressor, Battery coolant heater).




And, yeah, the Gateway firmware mismatch GTW_d001 is odd. Some parts in the Tesla powertrain have different firmware revisions than other parts. TPD will fix that, but . . . how did it get that way? Did you replace some Tesla part? Or has it been working this way since you got it in 2020 . . . hmmm. Vlad had done a lot of work with these parts of various firmware revisions . . . Vlad, how does the car get into this state and still drive OK?

I would think that a "Check EV System" MIL would have been triggered for that situation.

---


The "Battery Return Information: Minimum State of Charge" field is a SOH?

 

[Improve_RAV4EV]

I don't recall this, but stored codes could be read without activating the HV side; however, the Gateway doesn't like to store codes

Sorry, actually was hokiematt who suggested it.
And for the sake of laziness, I jumped on it.

???
This isn't a Tesla car, there are no electrically-applied parking brakes. It's a typical drum-brake-inside-rotor Toyota design. Same as most Toyotas of the period. Heck, it's the same as my Sienna.

I think I should've said "wheel lock", not parking brake.

The HVIL error BMS_f008 will prevent the BMS from closing the HV contactors,

I hear the contactors when I turn the car ON (a rather loud click).
I think I also hear them again when I turn it OFF.

With an HVIL error, you don't get HV and you can't complete a charge test session, so find the cause of the HVIL problem first. If the HV Service Disconnect (under passenger seat) is fully seated,

It is fully seated. I heard the clicking sound of the plastic lip.

it's almost certainly one of these:

1) The yellow (with black tape) HVIL loopback wire on the pass. side of the OBC:

Loopback connector is in place.

2) The translucent plastic cover on the HV terminals on the DC-DC (the cover must be in place, even if the wires underneath aren't), or one of the HV KET connectors isn't fully plugged in on the DC-DC (Cabin Heater, A/C Compressor, Battery coolant heater).

HV cables are connected and the cover is on.
So are other cables you mentioned.
Ground cables to OBC and to Heater are connected too.
Please see attached pic.

And, yeah, the Gateway firmware mismatch GTW_d001 is odd. Some parts in the Tesla powertrain have different firmware revisions than other parts. TPD will fix that, but . . . how did it get that way? Did you replace some Tesla part? Or has it been working this way since you got it in 2020 . . . hmmm. Vlad had done a lot of work with these parts of various firmware revisions . . . Vlad, how does the car get into this state and still drive OK?

I would think that a "Check EV System" MIL would have been triggered for that situation.

I haven't replaced any parts at all. But, I have no idea about the previous owner. He didn’t give me the repair and service records because he didn’t want me to see them, as the car warranty had expired.

 

[Improve_RAV4EV]

BTW, I wanted to connect and check the TechStream results too, but I think I got the wrong SW: (TechStream_VirtualBox-7.0.2-154219-Win.exe)
Could anyone provide me a link to download it please?

 

[alflash]

BTW, I wanted to connect and check the TechStream results too, but I think I got the wrong SW: (TechStream_VirtualBox-7.0.2-154219-Win.exe)
Could anyone provide me a link to download it please?

1. Warning. This is a very bad and harmful version, hacked by the Chinese more than 10 years ago. To avoid bugs of previous versions, I recommend using the original and latest Techstream v.18.0.008.

2. Use/turn on subtitles with translation into the desired language.

 

[alflash]

... I haven't heard of anyone checking that before . . . but, for this vintage of CAN bus, ~60Ω is correct.

1. The CAN bus resistors of this line usually have a tolerance of >1% and the accuracy of Chinese DVOMs is not ideal.
2. The result of checking the resistance* of a working CAN bus and other examples.

And, yeah, the Gateway firmware mismatch GTW_d001 is odd. Some parts in the Tesla powertrain have different firmware revisions than other parts. TPD will fix that, but . . . how did it get that way? Did you replace some Tesla part? Or has it been working this way since you got it in 2020 . . . hmmm. Vlad had done a lot of work with these parts of various firmware revisions . . . Vlad, how does the car get into this state and still drive OK?

I would think that a "Check EV System" MIL would have been triggered for that situation.

1. Outdated calibrations never cause trouble codes. Updates are made according to TSB or Safety Recall (in this case for 2012-2014 Model Year RAV4 Electric Vehicles - link above).
"In the involved RAV4 EV’s, components in the Electric Vehicle raction Motor Assembly, which is part of the propulsion system, may cause the vehicle to shift to “neutral” due to a software issue. This ondition will also trigger a “Check EV System” warning message on the instrument panel and turn on a malfunction indicator lamp.
If the vehicle shifts to :neutral”, this will result in a complete loss of drive power, which can increase the risk of a crash".

2. I don't know that this vehicle has alert code (GTW_d001) about firmware mismatch.
An example of a Hardware Config mismatch, when in Gateway instead of this set https://forum.alflash.com.ua/download/file.php?id=3044

after replace BMS this https://forum.alflash.com.ua/download/file.php?id=3475

Note. Unfortunately, I don't have the file fwupdate-1.3.XXX-vhcid_9.pet

3. Updating to 1.3 101 is necessary to eliminate the risk of spontaneous unexpected transition of the car from D to N while driving.

The "Battery Return Information: Minimum State of Charge" field is a SOH?

This parameter is equivalent to SOC (for TPD v1.1.42)..
About the essence of Battery Return & Shipping https://alflash.com.ua/2019/to_rav4ev/bat_ret_46a.png

These panels list the information required for returning a battery to Tesla from the field for remanufacturing.
OK to Ship by Land: Needs to be set for safe shipping via land OK to Ship by Air: Needs to be set for safe shipping via air Refer to the HV Battery pre-transportation evaluation form for other requirements on afe shipping.
If the HV Battery on a vehicle needs to be replaced as per diagnosis and if “Ok to Ship” bit(s) are not set-
• If the contactors close: The HV battery should be discharged to a safe
shipping level on the vehicle by turning on all the accessories – Cabin Heater or A/C, Seat Heaters, High Beam etc
• If the contactors fail to close: Coordinate with Tesla Service to perform a manual discharge of the HV battery out of the vehicle

* For example, https://alflash.com.ua/2019/to_rav4ev/can_res.jpg