Other Fuel System Problems of Toyota RAV4 - part 1

Toyota Rav4 le gas pump burst and caught fire leading to total fire damage along with major water damage from the firefighters putting out the fire. The vehicle was idle for hours at the time of explosion of the fuel pump. This was a major safety hazard/risk especially being that myself and two others were minutes away from going out to the vehicle before it all happened as I was getting ready to take a friend home for the night. A claim representative will look into this matter in coming days.

See all problems of the 2019 Toyota RAV4 🔎.

Strong gas smell when the engine is turned on. I started feel this issue about 2 year ago, now the gas smell is more stronger every time engine is turned on.

While traveling back from out of state, the fuel sensor and fuel gauge failed causing me to run out of gas when the fuel gauge stated I had just a tick under a 1/4 tank of gas left and the app read 35 miles left. While driving on freeway at freeway speed, the car sputtered, bogged down and then stalled, placing me in a very dangerous situation broken down on the shoulder of the freeway in the desolate country at night with semi trucks and cars flying by at estimated between 70-80 mph. While stalled and waiting for help, all the lights except the hazard flashers went out. The sheriff assisted and added 2 gallons of gas that finally got the car restarted and I was able to get to the gas station which was 1 mile ahead of where I had been stranded. I kept filling the gas tank not allowing it to go under 1/2 tank on the fuel gauge the remainder of the trip home. I took the car to tansky sawmill Toyota for service, who thought it was a fuel sensor in fuel tank, which had to be dropped, resulting in a tube from the fuel sender being disconnected and not taking fuel from the other side of the tank and corrosion was cleaned out. They had to go through electrical system to check the fuel gauge which had corrosion on the electrical harnesses and sensors not caused by water or rodents - still unknown cause - resulting in $6500. 00 to replace both electrical harnesses 82152-0r370 wire fr door lh and 82141-orb80 wire instrument panel! known Toyota defect as the 2019 Rav4 hybrids have already been recalled. Issues of this type with the regular Rav4s are posted all over the online Toyota boards. My platinum extended warranty on my well cared for 2019 Rav4 with 45,131 miles (purchased at 3 year lease end) refused to all of the charges and the dealership did not budge, sticking me with 6 hours of diagnostic fees over what the warranty allowed in the sum of $1014. 37. These harnesses need recalled so no one else is stranded in a very dangerous place on the side of the freeway!.

My 2019 Toyota Rav4 hybrid (VIN: [xxx] ) suffered sudden engine failure due to coolant intrusion. On Nov 20, 2025, johnstons Toyota in harriman, NY (ro#xxx) diagnosed the issue and recorded dtcs p26ca31 and p26cb, which indicate failure of the coolant flow control/bypass valve. The dealer confirmed heavy white smoke from the exhaust with a strong coolant smell and advised the engine had failed, recommending a replacement. This vehicle is part of the early 2019 japan-built batch widely known for premature electric water pump and coolant-flow system failures. Internal impeller swelling, seal leakage, and bearing seizure can cause coolant pressure spikes and ultimately head-gasket failure with coolant entering the cylinders. This defect has been reported by thousands of Rav4 hybrid owners (2019–2021). Toyota has addressed it quietly through internal tsbs such as xxx and xxx but no public recall has been issued. The safety risk is severe: the engine began emitting thick white smoke and ran roughly, risking sudden power loss, overheating, or engine seizure while driving. A stall at highway speed could easily cause a collision. Toyota USA opened case #xxx but declined assistance despite the defect being well documented. This failure was sudden, with no warning lights prior to the incident. Given the widespread nature of this defect and its clear safety implications, I request that NHTSA open a formal investigation into the electric water pump/coolant system failures in 2019–2021 Toyota Rav4 hybrids and consider requiring a safety recall. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Stopped for gas on 11/6/2025 immediately after getting gas the truck shook twice, the power steering light and engine shut down light came on and the truck turned off. Waited for a few minutes to turn the engine again it wouldn’t start. Got it towed to my nearest dealership who kept it for a day. Said there was nothing wrong with the truck, there was no code showing and they couldn’t determine the cause of the problem.

I stopped for gas; my car would not start. The power steering fluid light came on. I went inside to purchase some but when I returned to the car, there was no place to pour it. After a few minutes the car started. About a month later, my husband stopped for gas and the car killed right after he left the gas station, about 10 minutes later, it started. Took it to a mechanic, they couldn't find anything wrong with it because the check engine light wasn't on and the car wasn't giving any problem codes. About two weeks ago, I stopped for gas, the car wouldn't start. Finally got it started, and the check engine light came on. However, it's still not reading any codes.

1. My vehicle had a hybrid warnings and stopped running altogether, but the issue went away after clearing the codes. It came back at 105000mi, Toyota won't help with the $6000 repair. High voltage under floor cable and traction motor cable on my vehicle (2021 hybrid Rav4 xle registered in massachusetts) is affected by excessive and dangerous corrosion due to a Toyota design issue. 2. The vehicle could suddenly shut off at highway speeds per matt with service at autofair Toyota tewksbury. Sudden stoppage or deceleration may result in fatal collisions at speed. This failure also leads to fatally high-voltage energizing of the chassis and other frame components in some cases. 3. This is a known design flaw on Toyota hybrid, high-voltage cables/connectors, leading to excessive corrosion and dangerous failure of the hybrid system. There is an extended Toyota customer support program (csp: 22te09) valid through 8 years or 100000mi. I purchased the vehicle at 92,000mi but the dealership (carfive nashua, nh) and Toyota failed to inform me of this issue (a standard procedure per the csp) so I could make an informed decision and perform preventative maintenance. Toyota did send me notice of an airbag recall after purchase, so I know they had my information. Now they have left me without options at 105000mi. 4. Yes. It has been inspected and the high voltage cable corrosion confirmed by autofair Toyota tewksbury (MA). Image from diagnosis video attached. 5. Warning messages in obd2 screenshot attached. 6. I'm looking for Toyota to cover the repair for this issue; I've had to repair a valve head gasket and replace the ac system condenser already and this car is barely 4 years old.

See all problems of the 2021 Toyota RAV4 🔎.

Coolant bypass valve problem with several Rav4s. My car is unusable and I need it to work.

Sudden, unexpected, surprise surging idle upon placing the vehicle in park after driving a 15 minute distance at a top speed of 35mph. Loud surge up to 2. 5 (x1000rpm) sounds like the engine shifted idle drops down and immediately begins surging up again. Idle is high while driving. Some chugging upon acceleration. Immediately drove to auto parts store for diagnostic test. Started vehicle and showed technicians what was happening. Diagnostic test provided: code p0171 stored and permanent system is too lean bank 1 code p0505 stored and pending idle control system p117b stored fuel performance/direct injector most likely solution: replace fuel pump primary dtc: system too lean bank 1 suggested part: fuel pump operating the vehicle could result in sudden shut down, causing a collision. Could also cause compromised gas mileage and engine damage. Check engine light is on additional message states that all wheel drive mode has been disengaged and 2 wheel drive mode is active. No warning or any indication that there was any issues prior to the sudden idle surging upon placing the vehicle in park. I have searched existing recalls for 2019 Toyota rav-4 and found a fuel pump listed. I checked my license plate and VIN only to see the result that there are zero unrepaired recalls for both searches. This vehicle is clearly having an internal battle between air and fuel. I find it concerning that 2019-2020 Toyota rav-4 vehicles had a fuel pump recall and yet my search has provided these results.

Steering power low message appears and engine completely stops.

Check engine light came on as well as hybrid malfunction message. While on the highway could not accel or go past 60 mph, gas pedal would then not work and speed went down, I pulled car over to breakdown lane and car abruptly stopped and would not move. Many warnings flashed and car needed to be towed. Temperature rose and ignition messages came up, steering wheel locked and car was not drivable.

Was sitting in my car in the rain and all of a sudden the engine cut off. The check engine light came on and the error message on the dashboard said " engine power reduced". If I try to put it in anything but park, it won't let me. I have never had this issue, or any issue with this car. If I had been driving, this would have run me off the road.

See all problems of the 2023 Toyota RAV4 🔎.

Sudden surge and acceleration upon parking. I had brakes depressed pulling into a parking space when the vehicle felt like it jumped and quickly accelerated. It veered left missing the parked van in front of me but crashing into the parked Honda accord two spots over and one in front. It crashed into the back tire and fender area of the passenger side of the Honda pushing it completely out of its spot and sideways. My vehicle kept going even though pushing the brakes to stop. I had to force it into park to stop. The car’s air bags deployed but my Toyota’s airbags nor crash warning system worked.

Hybrid system failure resulting in vehicle not being drivable at all. Failure is due to corrosion from connector between high voltage harness into rear traction motor. Failure occurred 8,000 miles past warrantee cut-off (100,000) and will require weeks to months to fix 2/2 parts on backorder.

Dear NHTSA office of defects investigation, I am writing to formally report a safety concern with my 2021 Toyota Rav4 xse hybrid regarding its fuel tank capacity and refueling issue. Despite the advertised fuel tank capacity of approximately 14. 5 gallons, my vehicle only allows me to fill around 9 gallons before the pump automatically shuts off. This significantly reduces my driving range and forces me to refuel much more frequently than expected. After researching, I discovered that Toyota issued technical service bulletin t-sb-0109-20 acknowledging this issue, along with customer support program 20te04. However, my local Toyota dealership refuses to acknowledge the issue or perform the necessary repairs, despite my vehicle clearly experiencing the problem. I believe this poses a safety risk because: •the incorrect fuel level readings can lead to drivers miscalculating available fuel, potentially resulting in unexpected stalls or breakdowns. •it suggests a defect in the fuel tank design, which Toyota has acknowledged but has not proactively addressed with a recall. •many other Toyota Rav4 hybrid owners have reported similar issues, indicating this is a widespread manufacturing defect. Additionally, my wireless charging pad malfunctions and blinks constantly, raising concerns about potential electrical issues in a hybrid vehicle. Given the combination of fuel-related and electrical concerns, I am worried about possible safety risks that could arise from these defects. I am requesting the NHTSA 1. Investigate this issue further to determine if it qualifies for an official recall. 2. Require Toyota to take accountability and provide a permanent fix for affected vehicles at no cost to owners. 3. Ensure dealerships honor repairs for vehicles experiencing these known defects. I appreciate your time in reviewing this complaint. Please let me know if any further information is needed to assist in your investigation. Thank you.

My gas tank does not fill up properly. It seems to trigger the automatic shut off at gas stations when it is only 3/4 full. I then have to keep putting gas it with about 6 more shut offs to get the tank full.

All wheel drive disengages while driving. It has disengaged several times while driving up a steep hill in the rain resulting in loss of control of vehicle. First time car skidded into a ditch. Warning on dash said return vehicle to dealer. Vehicle has been returned 3 times. They blame the problem on a defect in the emission control system which turns off the awd system when a leak in the vapor control system is detected. Dealer first replaced the fuel filler cap. That worked for a couple of weeks, then something under the hood which worked a few days. Now the car is scheduled for a gasket on the fuel tank to be replaced for $1,500! I am all for controlling emissions to the environment, but it should not be at the cost of safety. A fix is needed to separate the awd from the emission control system. Safety first!.

See all problems of the 2017 Toyota RAV4 🔎.

Unknown.

After parking car in driveway, a puddle of fuel is left directly under fuel tank. Girlfriend thought it was ac condensation. I stuck my finger in puddle and smelled the gasoline. Girlfriend is taking car to dealer.

See all problems of the 2024 Toyota RAV4 🔎.

2023 Toyota Rav4 hybrid (xse) is said to have fuel tank capacity of 14. 5 gal with range in miles (city/hwy) 594. 5/551. 0 mi. When I first got my car, I can fuel it up to 520 mile driving distance. After a while, I can only fuel up to 430 mile, with no other accident. The tank cannot be fully fueled. This incidence has been widely observed in owners with the same year model. The actual reason is unknown. Some went to the dealership and replaced the sensor, some just got diagnosed with no issue. None of these has actually fixed the issue. The real answer could be the issue of the sensor or tank, or something else. This malfunction with unknown reason is risky for the use of the vehicle.

I was driving in the free way, my 2017 Rav4 started shaking and then stopped. I looked at my dash board it says: "charging system malfunction". I confirmed that I have 1/4 tank of fuel (reading the gauge). I had my car towed to a mechanic. Troubleshot it, found out that car was out of fuel but the fuel gauge said: 1/4 tank of fuel left. Reported the problem to Toyota. I was told they recalled other rav 4's , different years but not the 2017.

Dear NHTSA, I am writing to formally lodge a complaint regarding a recurring issue with my 2019 Toyota Rav4, which I believe poses a significant safety concern. The check engine light on my vehicle frequently illuminates, resulting in the disablement of the all-wheel drive (awd) system. I initially brought my vehicle to a Toyota dealership, where they replaced the charcoal canister (evap) three times based on the diagnostic code. Despite these repeated repairs, the problem persists. Suspecting that the issue might be related to the dealership's service, I sought a second opinion from another Toyota dealership. Unfortunately, they provided the same diagnosis and solution, which again failed to resolve the issue. Given that the awd system is a critical safety feature, especially in adverse driving conditions, I believe this issue should be considered a safety concern and potentially covered by a recall. Further given that the evap system is directly tied to the fuel it also should be considered a safety concerns. The repeated failure to address the root cause of the problem not only undermines the reliability of the vehicle but also compromises the safety of its occupants. I kindly request that the NHTSA investigate this matter and consider issuing a recall to address this widespread issue. Your attention to this matter would be greatly appreciated, as it would ensure the safety and satisfaction of Toyota Rav4 owners. Thank you for your time and consideration. [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Coolant bypass failed at 55,000 miles. This car has barely been used. This car is almost in mint condition and the coolant bypass has failed resulting the car not being able to be driven at all until fixed. The dealer is charging over $600 to repair. This is an ongoing issue with hundreds of Toyota Rav4 owners.

See all problems of the 2020 Toyota RAV4 🔎.

I was told on 6/28/2024 that my car needs a new coolant bypass valve at a cost of 900. 00 on researching this I see there is a class action suit against Toyota because there are so many people with this problem and it should be a recall. Not sure where to go from here .

After pressing the accelerator pedal, I released the pressure on the pedal because of traffic and the accelerator continued to accelerate. Had to hold the brake pedal down and then shifted to park and shutoff engine. When restarted the car operate normally. This has happened in the past and is very scary and unsafe. My internet research on problem shows that there have been two problems associated with this occurrence. One, accelerator trapped by floor mats and the second was because the accelerator pedal could "stick". The floor mats are secured by manufacture securing systems so it must be the in the sticking pedal. I am contacting Toyota but not optimistic. . . Is there anything the nhta can do for Toyota at least checking my car for a sticking accelerator pedal sticking. Finally, has there been any other reports of this happening?.

See all problems of the 2011 Toyota RAV4 🔎.

1. I had to have injector fuel service due to my vehicle having a sluggish feeling while driving from stop to start. The vehicle also had a throttling motion while driving. 2. A message appeared on dashboard after a recent visit to the dealership after normal maintenance service, “engine maintenance required” “reach out to dealer. ” this message specifically shows while I start up my vehicle and will not disappear if cancelled. “this is a warning for a coolant bypass valve failure”.

"engine maintenance required see dealer" message keeps appearing on my bashboard took it to my local Toyota dealer and they confirmed the problem is the coolant bypass valve/hose $150 to find the find the problem and $700 to fix apparently this is common in 2019-2022 Rav4s. Now my car won't drive for long without over heating I have only had my car for a year and a half and drive less than 5,000 a year.

Bypass coolant valve is a known issue and while the valve isn’t broken or leaking the car is prompting for a fix that isn’t necessary of a fix.

Fuel injector failed, causing the engine to run extremely rich, misfire, and cause severe drivability issues. Issue occurred just outside vehicle base warranty. Problem was verified and confirmed by vehicle dealership. Mil was illuminated when drivability issue and malfunction started.

See all problems of the 2022 Toyota RAV4 🔎.

Fuel pressure line leaking gas.

A week prior to this incident, the 2020 Rav4 was taken to Toyota for its maintenance check where everything was checked, replaced and changed. However, the last two days an incessant message keeps popping up on the dash stating “engine maintenance required… visit your dealer” taking up the entirety of the middle screen inhibiting my ability from seeing my speed, mileage, distance to empty , time, lane assist and other car information that I normally rely on. I have pressed the “arrow back” or “back” button numerous times but three seconds later the message pops again inhibiting me from being able to use necessary car controls to stay safe. The engine on the 2020 Rav4 needs to be recalled as my car only has 55,000 miles on it. I have talked to numerous professionals within the motor industry in which they state these engines have lower stability and life expectancy than previous engines used in older Rav4 models. Not only the engine, but the messaging system within the Rav4 needs to be fixed immediately as the communication of maintenance while driving is a hazard. If I cannot look at texts to even just simply read it, why is there is message bright and in the middle of my dashboard popping every 3 seconds with a bright red triangle stating that I need “engine maintenance required,visit a dealer”. This is a safety issue and one in which almost nearly cost me my life.

Vehicle was taken in for a oil change. At check-in I was told that I would be given a rental vehicle due to the overhead rails recall, leaking inside the vehicles at that time I advised of a gas smell which I have been smelling for several years and it was getting stronger. I was told that there was something wrong with the fuel pump and it would need to be replaced and they would also be replacing rails from the top of my vehicle because there was water leaks inside my car, I advised that water has been leaking in my car for several years and clips were already placedbout two years ago. Several days later I received a phone call that my vehicle was ready to pick up when I got there I was informed that the fuel pump assembly was replaced and intake. Manifest gasket , throttle gasket , fuel pump gasket replaced egr valve replaced egr inlet gasket replaced egr valve. Ad gasket replaced egr cooler gasket replaced. I was also told that my air filters would need to be changed and I did consent to my air filters, the air element and a brake system flush as recommended after picking up my vehicle which had 34033 miles on it on 1/24/24. On 2/10 I was driving and a warning flashed on my car and spoke to me it said that there was a malfunction detected in the engine, transmission or throttle of the vehicle and I need to contact Toyota. I was two miles away and drove directly to them. They took the vehicle for several hours. I was told it was the alternator because my lights have been going dim and very bright. I advised that I have issues with the windows closing since the most recent repair as well and the vehicle is losing power. After almost 4 hours I was informed it a thermostat. Everyone had gone home and they could not give me a give me a rental so I had to drive this vehicle until Monday afternoon. The thermostat and gasket were replaced and I was charged because they used insurance without telling me. I believe this is a malfunction in their system related to origina.

In at least 5 or more instances the vehicle has had unintended acceleration and thrust the car forward while I was braking and trying to come to a stop. Once it happened at a 4-way intersection and propelled my car into the middle of the intersection and I had to swerve to avoid a head-on collision with another car. I , or the other driver, could have been killed. In all cases the braking failed to stop the car and in fact sped it up even though the brakes were applied.

See all problems of the 2013 Toyota RAV4 🔎.

A strong fuel odor was evident in the cabin, and also under the hood after operation. Vehicle use was low, approx. 6k miles from new. My wife reported this to the dealer service department. They said nothing was wrong with the vehicle. Approx. 2k miles later, I reported the same problem to the dealer. Service rep said vehicle was unsafe to drive due to over torqued and leaking fuel line. They repaired it for no charge. No fuel vapors now, but if this is a production quality issue that others have reported, only to be told nothing was wrong, I think a major fuel-combustion safety issue may be overlooked. I am submitting documentation. Also, I am concerned about health effects of sustained fuel vapor exposure over months of driving. My wife rear-ended a stopped vehicle, possibly due to cognitive impairment from fuel vapor exposure. No warning indicators were ever triggered. Thank you.

This vehicle was involved in a t-bone crash, where the battery came out and the vehicle caught fire. The driver of this vehicle died at the scene. This involves NHTSA recall number 23v734 & manufacturer recall number 23tb13.