Engine Exhaust System Problems of 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.

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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.

The contact owns a 2011 Toyota Rav4. While driving approximately 70 mph, the contact smelled a strong odor of sulfur exhaust fumes emitting inside of the cabin. The failure would occur when driving at high speeds. The vehicle was taken to an authorized dealer where they were able to smell the strong odor. There was not a remedy to correct the defect. The failure mileage was 5,200.

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The contact owns a 2006 Toyota Rav4. The contact stated that upon starting the vehicle, the check engine light was illuminated on the instrument panel. The vehicle was taken to an authorized dealer where the contact was informed the vapor canister needed to be replaced. The contact was also informed that the vapor canister was responsible for removing harmful fumes from the vehicle. The vehicle was not repaired. The contact expressed concern over the harmful fumes presenting a fire hazard. The failure mileage was 67,000.

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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.

I have taken my 2002 Rav4 to Toyota on a few occasions. Every time it has been an oxygen sensor or fuel sensor. We had these replaced and now Toyota is telling us we need to replace the entire catalytic converter ($1000). The transmission, according to them, is not fully functional.

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Toyota 2001 Rav4: check engine light has been on since at least August, 2004 (documented). Toyota claimed to fix per a recall notice. From February 2002 to date, there has been intermittent groaning beneath car, whining in first gear, and what felt like clunking. Could not pass smog tests because of check engine light code. In October, 2009, car died. Could not restart, had to wait for tow (midnight on a dark road). Had work done in oct, 2009, and I requested the parts. They replaced my coils, plugs and air filter for $1,330. I have had brakes replaced , fluids changed, O2 sensors replaced ( since then, the car is mis-shifting, clunking or groaning, rough engine. On 3/25/2010, I took it in and Toyota service recommended that I "let it go" and buy another car. They told me to just come and get the car without any work done, because it would cost me between $6,000-$7,000 for repairs. I was never told that I had ecm and transmission problems throughout all of these visits to Toyota service. I believe that Toyota "waited me out" so that they could just sell me another car instead of revealing the true cause of my problems. The ecm and transmission for this car is no longer available as a new item, so I would have to get a rebuilt transmission, which the defective ecm would end up destroying. I am afraid to drive the car because of the possibility that the transmission will fail.

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I purchased my 09 Rav4 in June 2009. I noticed an odd odor a few times while running the air conditioner & assumed it was from the exhaust form the cars in front of me. When I began using the heat in the fall, I started smelling a bad, burning, almost chemical smell coming out of the vents. On Dec 29, 2009, I took my car to the dealership & Toyota told them to replace the evaporator, cabin air filter & disinfect/deodorize the vents & that would fix the problem which they said was mold in the system. It is now Feb. 23, 2010 & the smell is back & my car is sitting at the dealership because it makes me sick to drive it. The service manager is waiting to hear from Toyota what to do next & says it is a problem with alot of Toyotas. Why hasn't there been an investigation &/or recall for this problem? it is a health issue for anyone inhaling that disgusting air from those vents. I think it needs to be looked into since I have found other complaints on-line about the same issues. Is the health/safety of Toyota owners not important to Toyota? other than this issue, I love my rav & I really would like to be driving it instead of the yaris they loaned me until mine is fixed.

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The car was lifted up to replace tires and somehow the exhaust system was pushed up and got stuck with the exit inside the bumper leading to a fire and melting the bumper. The car was taken to the car dealer and they explained that the tires place didn't noticed that the exhausted system was stuck up. The bumper was replaced at my own expense.

On freeway, other motorist notified me my car was "on fire!" I saw excessive smoke in rearview mirror. I took the next exit which was dixon, CA off interstate 80 west in California. The side of the freeway there is grassy, did not think it was safe to stop. . . I stopped the car and smoke was everywhere, coming up through the hood & under the car. This was tues, 2/3/09. I has the car serviced the fri before, 1/30/09 at Toyota vallejo in vallejo, CA. I called the dealership after calling aaa for a tow. The service advisor, ryan said "it couldn't have been from anything they had done. But there is an 'oil hose' that had been coming off alot of the Rav4's. " I was already upset & that made me livid!! if it were a known problem the dealership should have checked during the scheduled maint. My car was towed to lithia Toyota of vacaville #47 at 500 orange drive, vacaville, CA. Work order 394212. As of yesterday, 2/12/09, the assistant service manager, megan, told me there was no TSB she was aware of, yet the part that came off (vvti oil pipe) was not found at any other dealership or supplier in the united states, and was on order from Toyota in japan. I am furious that it appears Toyota was well aware of this problem and has failed to initiate any steps to prevent risk to its consumers. I am asking for a full investigation which hopefully will lead to a recall of the 2006 Rav4's and any other year this affects. Megan, the assistant service manager at lithia Toyota confirmed with my insurance adjuster, jose lara (geico 707-688-3318) the cost is covered under the powertrain warranty. . . . What about the cost of my life, and the lives of the other motorist surrounding me??? the risk of fire is never to be taken lightly. Please investigate this matter to avoid any cost of life.

This is my third Toyota. I have never owned a Toyota that smokes. I park my Toyota rav 4 for a while, and crank it up it and smoke comes out of the exhaust. This problem started with only 61, 000 miles. I am totally dissatisfied with this Toyota, and disgruntled with the poor quality of manufacturing of Toyota's vehicles. Unfortunately this will possibly be my last.

2006 Toyota Rav4 4wd, black gas fume hose dislodged from underside of vehicle on driver's side and then fell out in driveway as result of driving through puddle on highway during heavy rains coming home from work. Took vehicle to dealer for service the following day, service tech said that fume canister breather assembly attached to fume hose was missing and probably fell off on the highway while driving through puddle. Service tech replaced parts a couple days later after ordering it. Service advisor stated that part would not be covered under the manufacturer's warranty because it was due to damage and not defect - cost to owner $132 parts $50 labor. Went out of town for 5 days & did not drive vehicle. On 8/9/06 after having driven about 30 miles, the check engine light comes on including the vsc and 4wd indicator lights, no performance degradation noticed. On 8/12/06 brought the vehicle into dealer again to diagnose the problem. Service tech states that charcoal canister pump needed to be replaced due to valve not functioning properly. He added that the vehicle is safe to drive, but would be polluting the environment. Part is on order and will arrive next week.

Another driver was doing about 60 Wednesday night in the pouring rain and hit a low spot on the freeway that had about 3" of water in it. He didn't see it soon enough to avoid it so he just hung on to the steering wheel and prayed. The car slowed down quite a bit but kept going straight spraying water everywhere. The noise from the water hitting the underside of the car was deafening. The next day the check engine light, vsc light and 4x4 light, came on. He stopped by the dealer on his way home to have it checked. He was in the waiting room a few minutes when the service mgr. Came and got him saying he wanted to show him something. They went out side and he pointed to the vehicle. There were two hoses hanging from the car below the drivers seat. It seems there was a plastic canister behind the charcoal filter that recircs tank fumes back to the engine. It got ripped off when he hit that puddle. He explained to him what had happened and he told him that warranty wouldn't cover the damage (~$150. 00). He told him that he had never lost car parts by driving through a puddle in all his years of driving. He was unsympathetic to say the least. The worst part about this is the parts are on backorder from Toyota and they don't know when they'll have them. Until then, the lights were on on the dash.

Engine light on two different times. Repaired 2nd time on warranty for $1500 for catalytic conv, 4 egr sensors etc. I fear I will pay next time out of warranty. Bought new. Well maintained, by the book.

I am experiencing a 5 to 10 second dead spot in the acceleration of my new Rav4 several times a week. Based on internet web page forum postings, I have found other new Rav4 owners that have the same problem. I have been told by the dealer that sluggish accleration is the result of a new emmisions control computer. This is beyond sluggish, the car barely moves. Pulling into traffic, accross streets and intersections, I am at risk and never know if the car is going to move or not. A new emmisions control computer has been installed in ravs since 4/01 so this problem appears to be new. I'm not getting anywhere with Toyota on this, and neither are the other owners that have this problem.

Consumer states exhaust fumes could be smelled inside vehicle.