2021-2022 Toyota MIL ON with DTCs in Freezing Temperatures

Some 2021-2022 Toyota Avalon, Camry, and RAV4 vehicles equipped with the A25A-FKS engine may experience a Malfunction Indicator Lamp (MIL) ON condition and/or reduced engine power when exposed to freezing temperatures. This issue is typically accompanied by specific Diagnostic Trouble Codes (DTCs) related to the throttle body.

Toyota has released Technical Service Bulletin T-SB-0005-24 Rev1 to provide a repair procedure for these conditions. The bulletin, revised on February 7, 2024, updates previous guidance and includes a new section on required tools and equipment. Any previous printed versions of this bulletin should be discarded.

Symptoms

Owners of affected vehicles may notice a reduction in engine power, particularly in cold weather. The primary indicator of this issue is the illumination of the Malfunction Indicator Lamp (MIL) on the dashboard. This Toyota Camry MIL ON issue is directly linked to the presence of specific fault codes.

Fault Codes / DTCs

When diagnosing this condition, technicians will find one or more of the following throttle body Diagnostic Trouble Codes (DTCs) stored in the vehicle's system:

• P01201C: Throttle / Pedal Position Sensor / Switch “A” Circuit Voltage Out of Range.
• P210015: Throttle Actuator “A” Control Motor Circuit Short to Battery or Open.
• P210019: Throttle Actuator "A" Control Motor Circuit Current Above Threshold.
• P211172: Throttle Actuator “A” Control System Actuator Stuck Open.

Diagnosis / Trigger Conditions

The condition is specifically observed in freezing temperatures. Diagnosis involves confirming the presence of reduced engine power and/or a MIL ON light, along with one or more of the listed DTCs. If these DTCs are not present, this bulletin does not apply, and further diagnosis should follow the applicable Repair Manual.

Repair Procedure Summary

The repair involves replacing two key components: the fuel pump assembly and the Engine Control Module (ECM), also known as the Powertrain Control Module (PCM). The ECM logic and fuel pump assembly have been modified to prevent these conditions.

1. Confirm Condition: Verify that the vehicle exhibits reduced engine power and/or a MIL ON with the specified DTCs in freezing temperatures.
2. Remove and Replace Fuel Pump Assembly: The existing fuel pump assembly is removed and replaced with a new, updated part. Specific removal and installation instructions are available in the Toyota Technical Information System (TIS) Repair Manual for each model and model year.
3. Remove and Replace ECM (PCM): The Engine Control Module is removed and replaced with a new, updated part. Detailed removal and installation procedures are found in the TIS Repair Manual.
4. Clear DTCs and Test Drive: After component replacement, all Diagnostic Trouble Codes must be cleared using a Techstream diagnostic tool. The vehicle is then test-driven to confirm the condition is resolved.

Required Tools or Parts

This repair requires specific updated parts and specialized diagnostic tools:

• Computer, Engine Control (ECM/PCM): Various part numbers depending on the specific model and year. For example, new part numbers like 89661-07811 (for Avalon), 89661-0X601 (for Camry), and numerous others for RAV4 models.
• Tube Assy, Fuel Suction W/Pump & Gage: New part numbers 77020-06661 (Avalon) and 77020-0R051 (Camry/RAV4).
• Rear Seat Cushion Lock Hook: Part number 72693-##### (Qty: 2).
• Fuel Suction Tube Set Gasket: Part number 77169-##### (Qty: 1).
• Diagnostic Tools: One of the following Techstream units is required:
  • Techstream ADVi (TSADVUNIT)
  • Techstream 2.0 (TS2UNIT)
  • Techstream Lite (TSLITEPDLR01)
  • Techstream Lite (Green Cable) (TSLP2DLR01)
• Software: GTS+ software version 2024.01.002.02 or later is required.

Applicable Warranty

This repair is covered under the Toyota Federal Emission Warranty. This warranty is valid for 96 months or 80,000 miles, whichever occurs first, from the vehicle's in-service date. It's important to note that warranty application is limited to occurrences of the specific condition described in this bulletin.

Important Warnings

• Critical Component Replacement: The ECU's software is specifically calibrated to a particular fuel pump output. Therefore, BOTH the ECU and fuel pump MUST be replaced as part of this repair to ensure proper function and resolve the issue. Failure to replace both components will not resolve the issue.
• Diagnostic Procedure: If the specified DTCs are not present, this bulletin does NOT apply. Technicians should continue diagnosis using the applicable Repair Manual for other potential issues.

Owner Action

If your 2021-2022 Toyota Avalon, Camry, or RAV4 is experiencing a Toyota Camry MIL ON light, reduced engine power, or any of the listed DTCs (P01201C, P210015, P210019, P211172) in freezing temperatures, you should schedule an appointment with an authorized Toyota dealer. The dealer will diagnose the issue and perform the necessary repairs, which are covered under the Federal Emission Warranty if your vehicle meets the mileage and time criteria.

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Source: NHTSA ID: 11005155