Engine Exhaust System problems of the 2007 Toyota RAV4

In Dec 2014 my car exhaust was louder than usual, the repair shop noted that the front center catalytic converter was rusted and perforated and replace it at at cost of $1844. 11. In Jan 2017 Toyota issued special service campaign g0y regarding this exact issue, claiming it will either fix rusted systems or reimburse those whose systems were already rusted and replaced. I submitted my request for reimbursement, responded for a request for more paperwork, and was subsequently denied without explanation. Today when I called for more info, I was told that the decision cannot be appealed (nfi). She finally said that the repair shop note did not mention rust. When I pointed out it said holes, she was unmoved and said their decision is final. This is dishonest and ripping off customers. I would appreciate your assistance in this matter. I believe I fully meet the requirements as spelled out in their service campaign notice. I can provide additional paperwork as needed.

After the check engine, vehicle stability control & 4wd warning lights displayed on my 2007 Toyota Rav4 with 89,400 miles, I went to my local Toyota dealer for a diagnosis of the problem. Upon inspection and testing, their service advisor stated, "the emissions system has malfunctioned since water has leaked into the emission system & its charcoal canister". The source of the water occurred since the fuel filler tube housing no longer was properly attached/secured to the vehicle. This allowed rwater coming down the side of the vehicle to enter through the fuel filler door by the fuel cap into the charcoal canister. To remedy the problem, the fuel filler assembly along with gaskets, some electronic and the charcoal canister required replacement for the emission system to properly function and to be in compliance with epa standards. The total cost of the repair $1,400 which Toyota would not cover since it was not under recall, nor would they consider paying under my extended 6 yr 100,000 mile warranty since that expired July 5, 2013. I find it incredible that Toyota would not pay for these repairs since they involve emissions as well as a safety issues. Based on my review of various blogs covering Rav4's, this is a common problem and Toyota admits no fault. As with all issues with Toyota they deny they have design/safety issues with any of their vehicles - sudden acceleration, steering suspension & braking. It took me repeated service visits to get them to replace the front steering rack under my extended warranty. I feel my fuel filler assembly and charcoal canister repair is a safety issue since gasoline could easily leak out down the tube on gasoline overfill and cause a fire if it reached the exhaust system. 20 yrs ago I had a similar issue with a Honda which was repaired under a recall at no charge. Your assistance is greatly appreciated. Thank you.

The contact owns a 2007 Toyota Rav4. While driving approximately 65 mph, the contact smelled a burning odor and maneuvered to the side of the road. The contact noticed that the rear passenger side floorboard carpet and rear passenger side seat was engulfed in flames. The fire department was called to extinguish the fire and a fire report was filed of the incident. There was no personal injury. The contact stated prior to the failure, a loud noise and a leak emitted from the exhaust pipe. The vehicle was completely destroyed and towed to a savage facility. The manufacturer was not notified of the defect. The approximate failure mileage was 41,000. Updated 5/11/12 the consumer believed the muffler or the catalytic converter overheated and set the back runner mat on fire, as it was directly under the passenger seat. The vehicle became fully engulfed in flames in a matter of minutes. Updated 05/31/12.

Car began smoking from the exhaust. Engine lights came on. Pulled over. No oil. Filled with oiled, waited awhile and was able to drive car home. Later went to dealer and they suspect possible ring or valve failure and was advised to carry oil in the car and check oil level before and after driving to prevent engine seize. Contacted dealer and Toyota, but they claim since it is after the warranty and because we missed some of our scheduled oil changes they would not be responsible. However, I have read of others with the same problem even though they did all their scheduled oil changes.