Vehicle recall R/2023/206

Toyota RAV4 recall: DC-DC converter may have been damaged during production

DVSA recall R/2023/206 names the Toyota RAV4. It was launched 21 August 2023. It covers vehicles built 14 July 2020 to 26 May 2022.

Recall data updated 22 September 2026

Recall: R/2023/206
Launched: 21 August 2023
Issued by: TOYOTA (GB) PLC
Manufacturer reference: YGG27 (23SD-075)
Vehicles: 3,422 across the lines below

What can go wrong

The plug-in hybrid system of the subject vehicles includes a DC-DC converter that reduces the voltage of the electricity from the Hybrid Vehicle (HV) battery in order to charge the vehicle’s 12V battery. Contained within the DC-DC converter is a current rectifying module that is installed on the circuit board. Some of these modules may have been damaged during production by the supplier and could fail so creating a short circuit. This allows current from the 12V battery to continue to flow through the module and the module will generate heat. Under certain conditions if excessive heat is generated components within and outside the DC-DC converter could sustain thermal damage increasing the risk of a vehicle fire.

The fix

Replace the DC-DC Converter.

Models and build dates

As listed in the DVSA recall file. Vehicle numbers are DVSA figures for each line.
Model	Built	Vehicles
Toyota RAV4 (RAV4 PHEV)	14 July 2020 to 26 May 2022	3,422

Is a specific car affected? A recall lists models and build dates, not individual vehicles, so these pages cannot tell you whether one car is included. Enter the registration on the DVSA vehicle recall checker on GOV.UK, or give the vehicle identification number (VIN) to the manufacturer or one of its dealers. Buying used? Ask the seller for proof that any recall work was done.

Other recalls for these models

R/2023/279 On affected vehicles there is a possibility that the DCM may not complete the shutdown process within a specific period of time when the ignition is turned off causing the DCM to not restart at the next ignition cycle and making the e-Call function unavailable. As a result the vehicles do not comply with relevant regulations. 12 October 2023, Toyota Yaris Cross, Toyota Yaris, Toyota Highlander and others
R/2023/040 The Hybrid Vehicle Control ECU (HEV-ECU) contains software that could cause the hybrid system to shut down after driving continuously in EV mode in cold temperatures and when the accelerator pedal is rapidly pressed to further accelerate the vehicle. This could result in a loss of drive and an increased risk of a crash. 13 February 2023, Toyota RAV4
R/2022/326 The force-limiter in the seat belt retractor may not operate as designed 23 January 2023, Toyota RAV4
R/2021/315 THE EMERGENCY CALLING SYSTEM (eCall) MAY NOT FUNCTION WHEN REQUIRED 15 November 2021, Toyota Corolla, Toyota RAV4, Toyota Yaris and others
R/2021/104 There is a possibility that the exhaust gas recirculation cooler could develop an internal coolant leak 31 May 2021, Toyota Corolla, Toyota RAV4, Toyota Auris and others
R/2025/270 Combination Meter Reprogramming on Multiple Models 24 November 2025, Toyota C-HR, Toyota Corolla, Toyota Yaris and others

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Source

Contains public sector information licensed under the Open Government Licence v3.0. Source: DVSA vehicle recall records (RecallsFile.csv), recalls launched 1992 to 2026. Recall data updated 22 September 2026.

Recall wording is DVSA's, with capitals and punctuation tidied and American spellings such as tire, center and windshield given in British English. We list a recall when its make and model match a car or van family with at least 1,000 DVSA MOT tests from 2022 to 2025, and when the maker of the vehicle issued it.

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