Other Fuel System Tank Assembly problems of the 2019 Toyota RAV4 - part 1

134 problems related to other fuel system tank assembly have been reported for the 2019 Toyota RAV4. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2019 Toyota RAV4 based on all problems reported for the 2019 RAV4.

1 Other Fuel System Tank Assembly problem

Failure Date: 03/31/2021

Unable to fill gas tank so that the gauge reflects "full". Tank only shows about 7/8 of a tank.

2 Other Fuel System Tank Assembly problem

Failure Date: 02/01/2021

Fuel tank does not fill up all the way. Missing about 3 gallons.

3 Other Fuel System Tank Assembly problem

Failure Date: 01/01/2021

Gas tank will not fill up in the hybrid model. It stops at around 8 gallons, leaving almost 1/4 tank capacity. This has been the situation since I bought the car. The dealer is aware and verified the issue.

4 Other Fuel System Tank Assembly problem

Failure Date: 12/18/2020

Recall fix not available until late January possibly Feb. Until then driving with a possible fuel tank failure. ## #vpic# 1 - check digit (9th position) does not calculate properly #vpic#.

5 Other Fuel System Tank Assembly problem

Failure Date: 10/28/2020

The fuel tank will only take about 12 gallons of gas instead of it's 14. 5 gallon capacity. The dealer acknowledged the issue and I was told Toyota was working on a fix and would contact me when it was solved. Can this problem cause a safety issue. ?.

6 Other Fuel System Tank Assembly problem

Failure Date: 08/01/2020

My 2019 Rav4 le has a 14. 5 gallon fuel tank and only takes about 8 to 9 gallons of gas when I fill up from empty. When I first purchased the vehicle I was getting 450 miles per full tank and now the most I get is 330. I took the car to the dealer and they said that it was normal even though my car was getting 22 miles to the gallon and not 26 mpg which would be on the low end.

7 Other Fuel System Tank Assembly problem

Failure Date: 06/01/2020

We bought the vehicle used. When we try to fill the gas tank up it will only fill up about 3/4 of the way. This is a recurring issue with the gas tank. We took it to Toyota who only reset the computer. However, we are still having the same issue. Even though Toyota is aware this is a common issue, they said they do not presently have a fix and don't know when they'll have one. The fuel reading is not accurate and we are also not getting the full functionality of the vehicle we purchased. We were also not made aware ahead of time that this was an issue on the vehicle.

8 Other Fuel System Tank Assembly problem

Failure Date: 05/01/2020

The fuel tank on my 2019 Rav4 hybrid does not fill up to capacity and only allows to be filled up to around 10 gallons. I have tried sever different fueling stations, brands, and pump dispensers but none of them allow to car to fill up to it's full limit. Estimated loss of range is around 100 miles per tank.

9 Other Fuel System Tank Assembly problem

Failure Date: 03/10/2020

Fuel tank can not be filled to capacity - will only accept up to 10 gallons when capacity is over 14 gallons.

10 Other Fuel System Tank Assembly problem

Failure Date: 03/09/2020

Like many others who bought a new generation Rav4 hybrid (it seems to affect all trims as long as it's hybrid), I cannot get more than maybe 10 gallons in the tank. Advertised is 14. 5 gallons, and there is no such thing as a 4+ gallon reserve in a private vehicle, even commercial vehicles. Toyota responded with "call us" after 5 or 6 emails. I drained it of fuel driving from texas to California, let it run dry until it was electric only, then took it to the gas station (literally right around the corner from where I was), and it still clicked the pump off - to full (though it doesn't read full anymore, it sits just below "f") - at just over 10 gallons. I have squeezed every last drop I could once and it didn't even read 11 gallons from empty, though I don't normally ever do that so the evap canisters don't get burned out. The average mpg and estimated range on the screen adds up with the math for only having about 10 gallons in the tank, 36. 3 average with just over 10 gallons gives me about 300 miles, which is about what the odometer sees per fill from 1/4 full, when I usually fill up. It's been almost a year and Toyota has been of zero assistance even acknowledging this, though 2 dealerships in texas (where I bought it) told me it was a known issue, and 2 in hawaii (where I live now) repeated that info. Again, this is a hybrid xse - the premier model for sporting I wanted, the light sporting I do anyway, and it has other problems too. One is decades old with the Rav4 (window rattle), the other is with the a/c switching between modes. I can live with the other two, but not getting what was advertised in the fuel tank is worthy of complaint seeing as how many hundreds of others posted online about it this past year. Toyota needs to address this problem before it becomes yet another legal battle for them.

11 Other Fuel System Tank Assembly problem

Failure Date: 03/08/2020

Stationary problem. Unable to fill car completely. Takes a maximum of around 9. 5 gallons of 14. 5 gal tank. Stated range should be between 580 and 550 miles. Never exceeded 429 distance to empty, typically 392 miles dte with 36 mpg avg. Toyota is unresponsive to issue. I lack confidence in fuel computer and system.

12 Other Fuel System Tank Assembly problem

Failure Date: 03/03/2020

I'm unable to put no more than 10 gallon of gas even tho max gas tank is 14. 5. A lot less mileage than Toyota claim.

13 Other Fuel System Tank Assembly problem

Failure Date: 02/26/2020

When fueling, the tank will not completely fill. If you attempt to continue to fill very slowly the tank over fills and you have problems with the vapor recovery system.

14 Other Fuel System Tank Assembly problem

Failure Date: 02/26/2020

Fuel tank will not fill correctly. If I over fill it affects the vapor recovery system of the ra 4 hybrid. Have to be extremely careful not to run out or gasoline.

15 Other Fuel System Tank Assembly problem

Failure Date: 02/15/2020

I have a 2019 Toyota hybrid. The tank can not be completely filled. It can leave around four gallons unfilled. The only way I can fill it is to have the nozzle slightly out side of the filler neck and pump a a slow rate. While this works, it takes time and it is not very environmently friendly.

16 Other Fuel System Tank Assembly problem

Failure Date: 02/14/2020

2 issues with this brand new 2019 xse hybrid Rav4. 1) fuel tank never fills up as gas pump clicks off at 9. 5 (3/4 full) at gas station. This is now all over the news and blogs, and Toyota seems to have acknowledged the issue, but no solution yet . 2) after Toyota dealership performed brake recall service on Dec. 8, 2020 (at less than 2k miles), the front brakes whistles or squeaks loudly whenever I apply brakes at low speed (at or less than 5 mph). When I arrived at dealership to speak with service manager (scott), technician was assigned and rode with me and confirmed the low brake speed squeal/whistle. After 2-3 hours, a different technician who was assigned to look at it claims "no noise observed after test drive, operating as designed. " funny how they assigned 2 different technicians - one who observed the noise upon arrival, and the 2nd one who looked at it and claims no noise. When driving out of dealership service area, the low speed (<5mph) brake noise squeal was and is currently still there. Dealer continues to claim cold weather or moisture may be the cause (really - that sounds amazingly false!) and refuses to acknowledge or repair the brake noise issue. It's as if the dealership (stevens creek Toyota, san jose) is waiting for a recall vs. Acknowledging the issue so Toyota corporate will reimburse dealership for the repair cost for the brake noise issue. Car currently only has 4k miles.

17 Other Fuel System Tank Assembly problem

Failure Date: 01/29/2020

I bought my new 2019 Toyota Rav4 hybrid xse and took possession on January 3 2020. Since then, I have refuled multiple times and noticed it would not take more than 9-10 gallons of gas from empty. I found myself refueling more times than my previous vehicles. When researching prior to purchase, the vehicle says it has a fuel capacity of 14. 5 gallons and 580 miles per tank. I have never been able to get more than 9-10 gallons and it has always shown gas range in the 400 miles per tank. It has never given me anywhere close to 580 miles per tank. I took it today to the dealership after calling Toyota on January 30th and the dealership said that all cars have a 4 gallon reserve tank. This was their response to the problem although I am sure nobody would like to find out how many gallons a car has in reserve after the refuel light is on for obvious safety reasons. When I refuled all my previous cars, the capacity was at least what it said on the manual or more. It has never been a difference of over 38% from what the manual says to what this vehicle can actually take when refueling from empty with the refueling warning on and the refueling light on. It is dangerous to try and follow Toyota's official fuel capacity and range for this vehicle. If you follow the official range stated by Toyota in the manual and vehicle information, drivers can run out of gas thinking the car has actually 14. 5 gallons instead of 9-10 and a range of 580 miles instead of the actual 400 mile range.

18 Other Fuel System Tank Assembly problem

Failure Date: 01/21/2020

Didnt fill up gas tank and brake pressure is low. Its take too much space to stop.

19 Other Fuel System Tank Assembly problem

Failure Date: 01/07/2020

I purchased the new 2019 Rav4 hybrid on 11/29/2019 at prime motors in saco, maine. It currently has 725 miles on it. When I attempt to fill it it won't fill all the way. It's advertised to have a 14. 5 gallon tank but only holds about 10 gallons. The dealership advised me to keep pumping after the pump shuts off. This is very bad advice as it could overflow and cause a fire.

20 Other Fuel System Tank Assembly problem

Failure Date: 01/06/2020

The fuel tank capacity is about 9 gallons way too lower than the specification. This is causing too many trips to the gas station than expected. The purpose of buying a hybrid is defeated.

21 Other Fuel System Tank Assembly problem

Failure Date: 01/06/2020

The gas tank does not accept enough gasoline to fill the tank. Upon fueling, the dispenser clicks to stop when only 9-10 gallons are in the tank. The stated fuel tank capacity is 14. 5 gallons, thus the tank can only be filled to less than 70% capacity. The problem seems to be worse in cold weather conditions.

22 Other Fuel System Tank Assembly problem

Failure Date: 01/06/2020

Fuel tank capacity not as advertised (14. 5 gallons). Maximum input is 9-10 gallons after fuel light comes on. Vehicle is at 16,000 miles. Capacity problem has been consistent for life of the vehicle.

23 Other Fuel System Tank Assembly problem

Failure Date: 01/06/2020

Whenever I fill the car with gas, it doesn't get completely full. It leaves the tank about a quarter from full. Also, the car doesn't accelerate well. It hesitates.

24 Other Fuel System Tank Assembly problem

Failure Date: 01/06/2020

Our Rav4 hybrid will rarely fill more than 9-10 gallons in the tank. When the vehicle starts after a new tank has been filled the needle will not be all the way at full. One of the reasons I was sold on the vehicle was it's range, but this tank issue makes it impossible.

25 Other Fuel System Tank Assembly problem

Failure Date: 01/02/2020

My 2019 Toyota Rav4 hybrid gas tank will not accept over 9. 5 gallons at any time. Even when I have only 50 miles until gas tank empty showing on dashboard. It's a 14. 5 gallon tank so this is a problem.

26 Other Fuel System Tank Assembly problem

Failure Date: 01/01/2020

After waiting for 10 months, Toyota has still not delivered a fix for their known fuel tank capacity problem in their 2019 Rav4 hybrid model. Toyota continues to state that the 14. 5gal tank has a capacity of more than 500 miles, while owners struggle to put more than 9-10 gallons into the vehicle. The reduced range and inconsistent fuel level readings have left me unsure as to how much fuel the vehicle actually has, resulting in frequent fuel stops and an observed range of closer to 300miles.

27 Other Fuel System Tank Assembly problem

Failure Date: 01/01/2020

Vehicle refueling performance. The gauge does accurately reflect the contents of the gas tank. 14 gal tank empty will not take more than 8 gal of gas. Resulting in a safety issue as you never know when you are out of gas.

28 Other Fuel System Tank Assembly problem

Failure Date: 01/01/2020

Fuel tank capacity 14. 5 gallons can only be filled to 9. 5 gallons without aggressive "topping off". In order to avoid possible environmental harm and vehicle emission control damage, topping off not used. However, this leaves the vehicle 5 gallons short of a full tank (about 200 mile range loss).

29 Other Fuel System Tank Assembly problem

Failure Date: 01/01/2020

Toyota has misled consumers with 41mpg and falsely stated the size of the fuel tank. It's supposed to be a 14. 5 gallon tank, however it will only hold 10 gallons even when completely empty. If I try to put in more fuel in after 10 gallons it spits out fuel as if over full. I bought this hybrid Rav4 in an effort to make less frequent full ups. This defect is causing me to fill up more often than non hybrid vehicles.

30 Other Fuel System Tank Assembly problem

Failure Date: 12/30/2019

Tank was advertised as having a capacity for 14. 5 gallons. I am not able to fully fill the tank, only putting in 9 to 10 gallons maximum. Toyota has stated that they are aware of this problem and there is no fix. I am unable to get the mileage range I was promised upon purchase.

31 Other Fuel System Tank Assembly problem

Failure Date: 12/30/2019

The gas tank is quoted as having 14. 5 gallon capacity and I am only to fill up 10 gallons.

32 Other Fuel System Tank Assembly problem

Failure Date: 12/27/2019

Fuel tank will not fill to full causing attendees/user to trickle and attempt to trick the vehicle to accepting more fuel. Range of vehicle is greatly reduced as a result of less fuel available to a tank of gas.

33 Other Fuel System Tank Assembly problem

Failure Date: 12/27/2019

Fuel tank only holds 10 gallons, tank should hold 14 gallons. Reduces driving range and time to fuel up - which was the main reason we bought this car. When drove car off dealership lot, driving range was 440 - drove 6 hours without having to fill up. Driving range was never more than 340 after that and had to fuel up about every 3 hours. Reported to Toyota corporate.

34 Other Fuel System Tank Assembly problem

Failure Date: 12/26/2019

Advertised fuel tank capacity of 14. 5 but only able to us 9-10 gallons of the tank, will not fill up as advertised ~550 mile range. I bought this vehicle for the estimated driving range and we aren't getting anywhere close to that. Took to dealer and no explanation or action was given. Help.

35 Other Fuel System Tank Assembly problem

Failure Date: 12/24/2019

Could not fill the gas tank fully. It takes only 9. 834 gal of fuel instead of 14. 5 gal. This is widely reported problem, but Toyota seems not to issue any recall.


Other Other Fuel System related problems of the 2019 Toyota RAV4


Safety Ratings of RAV4 Cars
Fuel Economy of RAV4 Vehicles
RAV4 Service Bulletins
RAV4 Safety Recalls
RAV4 Defect Investigations