2021 Toyota RAV4 Prime Electrical Power Control Unit Recall (23V041)
Toyota Motor Corporation · 16,679 vehicles · Reported February 2, 2023
Toyota Motor Corporation is recalling 16,679 2021 Toyota RAV4 Prime vehicles. During certain cold weather driving conditions, while driving in EV Mode, the hybrid vehicle control engine control unit (HEV ECU) software may cause the hybrid system to shut down if the accelerator is rapidly pressed to further accelerate the vehicle, resulting in a stall. An engine stall increases the risk of a crash. Dealers will make the repair free of charge.
Recall 23V041 at a glance
| NHTSA campaign number | 23V041000 |
|---|---|
| Manufacturer recall number | 23TA01 |
| Date reported to NHTSA | February 2, 2023 |
| Manufacturer | Toyota Motor Corporation |
| Vehicles | 2021 Toyota RAV4 Prime |
| Units affected | 16,679 |
| Component | Electrical System > Propulsion System > Hybrid Management > Power Control Unit / Module (Hpcu) |
| Safety risk | An engine stall increases the risk of a crash. |
| Fix | Available at dealers |
What is wrong with the 2021 Toyota RAV4 Prime in recall 23V041?
During certain cold weather driving conditions, while driving in EV Mode, the hybrid vehicle control engine control unit (HEV ECU) software may cause the hybrid system to shut down if the accelerator is rapidly pressed to further accelerate the vehicle, resulting in a stall.
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021 RAV4 Prime Plug-In Hybrid vehicles. During certain cold weather driving conditions, while driving in EV Mode, the hybrid vehicle control engine control unit (HEV ECU) software may cause the hybrid system to shut down if the accelerator is rapidly pressed to further accelerate the vehicle, resulting in a stall.
Is it safe to drive a 2021 RAV4 Prime with recall 23V041?
NHTSA has not told owners to stop driving, but the risk is real: An engine stall increases the risk of a crash.
NHTSA describes the risk this way: An engine stall increases the risk of a crash.
There is no do-not-drive order on this campaign. If your RAV4 Prime shows warning lights or behaves differently in a way that involves the power control unit and module, have it checked before driving further.
Which vehicles are included in recall 23V041?
Recall 23V041 covers 16,679 vehicles: 2021 Toyota RAV4 Prime.
NHTSA lists 16,679 vehicles in this campaign. Not every vehicle of these models and years is included, so check your VIN.
| Model years | Make | Model |
|---|---|---|
| 2021 | Toyota | RAV4 Prime |
What is the fix for the RAV4 Prime electrical power control unit recall?
Yes. Dealers will update the HEV ECU software, free of charge.
Dealers will update the HEV ECU software, free of charge. Owner notification letters are expected to be mailed February 27, 2023. Owners may contact Toyota's customer service at 1-800-331-4331. Toyota's number for this recall is 23TA01.
When was recall 23V041 announced?
Toyota Motor Corporation reported recall 23V041 to NHTSA on February 2, 2023. NHTSA lists the owner letter date as February 27, 2023.
| Date | What happened |
|---|---|
| February 2, 2023 | Toyota Motor Corporation filed the defect report with NHTSA; NHTSA assigned campaign 23V041000. |
| February 27, 2023 | Owner notification letters scheduled (per NHTSA). |
This recall was filed 44 months ago. If your RAV4 Prime was built in that window, the VIN check below is the way to confirm it is included.
How do I check if my RAV4 Prime is part of recall 23V041?
Enter your 17-character VIN at nhtsa.gov/recalls. If recall 23V041 is open on your RAV4 Prime, it will be listed there.
Enter your 17-character VIN at NHTSA’s recall lookup. It shows any open safety recall on your vehicle, including 23V041000. Your VIN is on the registration card, the insurance card, and the driver side of the dashboard where it meets the windshield. Recent recalls can take a few days to appear in the lookup.
What should RAV4 Prime owners do about recall 23V041?
Check your VIN, schedule the free recall repair, and keep a repair order for every dealer visit.
- Check your VIN at nhtsa.gov/recalls to confirm recall 23V041000 applies to your RAV4 Prime.
- Book the recall appointment with any authorized Toyota dealer. Ask up front whether parts are available and how long the vehicle will be there.
- Get a repair order for every visit, even if the dealer only inspects the vehicle. Read it before you leave and make sure your complaint is written the way you described it.
- Keep a simple log of any power control unit and module symptoms with dates and mileage. Video of a warning light or the problem happening is strong evidence.
- Count the days the vehicle is at the dealer. Days out of service add up toward California's 30-day presumption.
- If the problem comes back after the repair, return to the dealer and contact a lemon law attorney.
What are RAV4 Prime owners reporting to NHTSA?
Owners have filed 99 complaints with NHTSA about these vehicles since 2020, 37 of them about the ev and hybrid battery.
Since recall 23V041 was reported on February 2, 2023, owners have filed 33 complaints with NHTSA about the ev and hybrid battery on these vehicles. 1 of them (3%) describe the same problem happening more than once or coming back after a repair attempt.
How we counted: we matched NHTSA owner complaints for the model years in this recall that list the ev and hybrid battery and were received on or after February 2, 2023, then flagged narratives that describe a repeat failure or a problem returning after a dealer repair, recall service or software update. Data from NHTSA, accessed October 1, 2026. Complaints are unverified owner reports and may involve a related ev and hybrid battery issue rather than this exact defect; automated text matching can miss or misread some reports.
NHTSA’s public complaint database lists 99 owner complaints filed since 2020 for the vehicles in this recall, and 37 of them involve the ev and hybrid battery. Complaints are reports from owners and have not been verified by NHTSA, but a high count for the same component is a sign the problem is widespread.
- 2021 Toyota RAV4 Prime: 99 complaints in total, 37 about the ev and hybrid battery
Examples of what owners have reported to NHTSA (unverified excerpts):
The vehicle generated an error message "Plug In Charging System Malfunction" warning on the dash. The remedy is a Toyota T-SB-0021-21 which requires a software upgrade to fix the air fan sensor reading to the charging unit.
2021 Toyota RAV4 Prime owner, WA, NHTSA complaint 11734723, filed April 29, 2026
Observed arcing noises and strong electrical fire smell upon plugging in L2 EVSE charging cable. MIL lit, Hybrid Vehicle Charging System codes active; vehicle refused to charge afterwards. Self-diagnosed and repaired defective 6.6 kW onboard charger. See pics of clear arcing damage withing charging unit – possible fire risk.
2021 Toyota RAV4 Prime owner, TX, NHTSA complaint 11742590, filed June 7, 2026
The 2021 RAV4 Prime has a known defect with the heat pump causing an alarming sound to be heard within about a 1 minute of startup. The grinding noise causes distraction as it is extremely loud and occurs generally while backing out/maneuvering in tight areas.
2021 Toyota RAV4 Prime owner, CO, NHTSA complaint 11443354, filed December 10, 2021
Can recall 23V041 make my RAV4 Prime a lemon in California?
Not by itself. A recall repair that fails, or repeat dealer visits for the same defect, can support a California lemon law claim.
Recall 23V041000 does not automatically make your RAV4 Prime a lemon. California's Song-Beverly Act asks two questions: does a warranty defect substantially impair the vehicle's use, value or safety, and did the manufacturer fail to fix it in a reasonable number of tries (Civ. Code 1793.2(d))?
Battery and electric drive repairs are among the slowest repairs in the industry. A 2021 Toyota RAV4 Prime waiting on a battery module or drive unit can sit at the dealer for weeks, and every day counts toward the 30-day figure in California's lemon law presumption.
The recall repair is available at dealers. If it works, great. If the same symptom comes back, the recall visit is one repair attempt and the next visit is another.
Civil Code 1793.22(b) sets out a presumption that applies in the first 18 months or 18,000 miles: two or more repair attempts for a defect likely to cause death or serious bodily injury, four or more attempts for the same defect, or more than 30 total days out of service for repairs. Written notice to the manufacturer is required in some cases. Owners outside that window can still have a claim.
An owner who prevails in a lemon law case can recover reasonable attorney fees and costs from the manufacturer (Civ. Code 1794(d)). You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.
In our cases, a recall repair visit counts as a repair attempt, and it's strongest when the owner complained about the problem before the recall came out. A recall shows the defect is real and that enough owners reported it for the manufacturer to issue a fix.
Recall repairs depend on parts. Owners can wait days, weeks or months, usually about one to three months in our cases, and those days count toward California's 30-day out-of-service rule.
The biggest mistake I see is waiting too long. The mileage offset starts at your first repair visit for the problem, so the sooner you take it in, the better. If the problem comes and goes, take it in when it happens. You can't go back to that date later.
If you get a recall notice, call a lemon law attorney right away. You may have taken the car in for the same problem before and forgotten, or there may be other recalls related to it.
Jacob Shayesteh, Esq. (SBN 362320), Founder and Managing Attorney. Quotes lightly edited for clarity. Prior results do not guarantee a similar outcome.
Has your RAV4 Prime been back to the dealer for this problem?
Call 877-536-6620Other Toyota RAV4 Prime recalls
Frequently asked questions about recall 23V041
Did the recall 23V041 fix work?
Since recall 23V041 was reported on February 2, 2023, owners have filed 33 complaints with NHTSA about the ev and hybrid battery on these vehicles. 1 of them (3%) describe the same problem happening more than once or coming back after a repair attempt. If your vehicle still has the problem after the recall repair, go back to the dealer, get a repair order, and talk to a lemon law attorney.
When will owners be notified?
According to NHTSA, owner notification letters were or are scheduled to be mailed February 27, 2023.
Is the 23V041000 recall repair free?
Yes. Safety recall repairs are done free of charge at authorized dealers.
How do I know if my RAV4 Prime is part of recall 23V041000?
Enter your 17-character VIN in NHTSA's recall lookup at nhtsa.gov/recalls, or call a dealer. The VIN is on your registration, insurance card and the lower corner of the windshield.
Can a battery recall reduce my EV's range?
Some battery recalls limit the state of charge or range until a module or pack is replaced. Check your owner letter for any interim limits, and keep notes if range or charging changes after the repair.
Does the recall fixing my car mean I have no case?
Not necessarily. Even if the recall repair fixed it, you may still have a case, and a car that's a year or more old can still qualify.
Do used cars qualify for California lemon law?
We take certified pre-owned, demo and dealer vehicles. Since the California Supreme Court's Rodriguez decision in 2024, ordinary used cars generally do not qualify.
How long does a recall lemon law case take?
Recall-related cases typically resolve in one to three months from your first call. Prior results do not guarantee a similar outcome.
What does a lemon law attorney cost?
You pay nothing, win or lose. We are paid only if you win, and the manufacturer pays our fees, including in settlements. If a case is lost, our firm covers the costs.
Sources
- NHTSA recall record 23V041000 (recall report and owner letters are posted there)
- NHTSA complaints and recalls data, accessed October 1, 2026
- California Civil Code 1793.2 and 1793.22
Attorney advertising. America’s Lemon Lawyer is a trade name of Wynn Law Group, APC. Responsible attorney: Jacob Shayesteh, Esq. (SBN 362320). This page is general information, not legal advice. America’s Lemon Lawyer is not affiliated with NHTSA or Toyota. Prior results do not guarantee a similar outcome.