Other Fuel System Tank Assembly Problems of Toyota RAV4 - part 1

Toyota RAV4 owners have reported 199 problems related to other fuel system tank assembly (under the other fuel system category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Toyota RAV4 based on all problems reported for the RAV4.

1 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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.

See all problems of the 2019 Toyota RAV4 🔎.

2 Other Fuel System Tank Assembly problem of the 2021 Toyota RAV4

Failure Date: 03/08/2021

Car had a low fuel indicator on (approx. 15miles distance to empty left on a dashboard). Upon refueling, the car only took about 11. 38 gallon of fuel to refill the empty tank. This is very annoying as I just bought this car new thinking it has 14. 5 gallon fuel tank capacity but in reality it has a defective fuel tank and it only takes about 11 gallon of fuel.

See all problems of the 2021 Toyota RAV4 🔎.

3 Other Fuel System Tank Assembly problem of the 2021 Toyota RAV4

Failure Date: 03/07/2021

The gas tank of 2021 Rav4 hybrid does not fill in as advertised. Toyota advertises that it can take 14. 5 gallons of fuel, however when the fuel low warning light is on and you try to fill the full tank, it never takes more than 10 gallons, thus there's discrepancy of 4 gallons. This reduces the car's advertised range from 550 miles to less than 400 miles. Toyota claims this is a design mistake and doesn't offer any fix.

4 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 02/24/2021

The mileage I am getting is far below the stated rating on the sticker. I am averaging about 33. 5 mpg in mixed driving whereas the stated rating is 41 mpg overall. It's not even close. The tank was recently replaced because you could not fill the tank. Extremely disappointed in the mileage which was the main purpose of buying this vehicle. Something needs to be done.

See all problems of the 2020 Toyota RAV4 🔎.

5 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

Failure Date: 02/01/2021

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

6 Other Fuel System Tank Assembly problem of the 2021 Toyota RAV4

Failure Date: 01/30/2021

Cannot fill fuel tank completely full. Had some tests run by Toyota and they found that there were only 12. 5 gallons in the 14. 5 gallon tank when the pump shuts off. I was told this was "within the spec" and offered no further help.

7 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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.

8 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 12/20/2020

Toyota states the Rav4 hybrid has a 14. 5 gal gas tank. When gas gauge showed 27 mi left, I was only able to put 11. 8 gal in tank. Dealer told me to just assume I had more gas left. This was after they had repaired the recall on the tank approved by Toyota. No way to know how far I could go. The recall didn't work.

9 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 12/20/2020

Vehicle gas tank will not fill to capacity. . I am stoping at gas stations all the time because I am flying through gas . . And it's a hybrid . . Won't fill more than 9 or 10 gals . . The vehicle has no range for a hybrid which is the exact opposite of what they say when they're trying to sell you one. . Had I known I would be at a gas station every 3 day's with a hybrid I would have never bought it.

10 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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#.

11 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/28/2020

Can not fill fuel tank to full. Only about 11 gallons when it should be at 14. 5. Can not get mileage told it should get.

12 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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. ?.

13 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/23/2020

So I knew before buying this car that it had a defective fuel tank design. The shape of the tank doesn't allow for the fuel vapor to circulate properly which in turn makes the fuel wand think the the tank is full when it really isn't even close. That being said, I told myself if I noticed this defect, that I would submit this report because it's the only way Toyota is going to fix it for later customers. This isn't a safety issue so I fully expect to never see a recall out of this and all of us are just going to have to deal with it. The first sign that I received a defective fuel tank was when my first tank of gas only got me 400 miles. This vehicle, if filled completely should get you at least 500 to 530 miles on mixed driving. So I pulled into the station and sure enough, the fuel handle stopped at 12 gallons. That's with about a gallon in the tank already so really about 11. I then proceeded to fill the tank the rest of the way at about 1/4 gallon increments and after 10 minutes, I finally got it to 14. 5. Not topped off at all, just to the top of the tank + or - a quarter gallon. So again, my reason for posting this is not that I'm mad or surprised this happened, it's just simply to do my part in trying to get Toyota to do right by their customers and fix this issue. This problem continues to puts a small but still annoying black mark on an otherwise amazing vehicle.

14 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/18/2020

I have been having an issue with the gas tank of my 2020 Toyota Rav4 hybrid le. The tank can never be filled to it's full capacity of 14. 5 gallons. I can only add 9 or sometimes 10 gallons and the gas tank gauge shows only 3/4 of the tank filled affecting the mpg and the range of the vehicle.

15 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/16/2020

Fuel tank does not fill completely and shows inaccurate reading on the driver console.

16 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/13/2020

The gas tank is rated at 14. 5 gallons. I have not been able to get more than 10 gallons of gas at fill up once I have gone 30 miles after I have 0 miles remaining to fill up. I can not go anywhere near 580 miles as Toyota has stated. I do get around 43 mpg driving in city traffic only.

17 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/01/2020

Fuel gauge/fuel tank problem. Tank holds 14. 5 gallons, but automatic shut-off allows only 10 gallons. Fuel gauge then shows "full. " displays and fuel-low warnings come on after about 400 miles, with fuel gauge showing "empty. ".

18 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 10/01/2020

Fuel gauge does not correctly show volume in the gas tank. When gauge reads empty and light comes on only 9-10 gallons of fuel will completely fill the tank. Supposedly capacity is 14. 5 gallons.

19 Other Fuel System Tank Assembly problem of the 2010 Toyota RAV4

Failure Date: 09/27/2020

When I slow down to approach a stop sign or wait to make a turn on a city street, the car stalls. It happens with left hand and right hand turns. I have to put it in park and start it again. It has happened over weeks. I put 3/4 of a tank of premium gas to see if that helped and it stalled on the way home. It can stall 3-4 times in a day or not at all. The cause is unknown. I brought it to a private mechanic shop and they could not find a cause. I notice a 'rattling' noise now when I start the car. I am afraid that I may turn in front of a car and stall so that the car will not accelerate when I expect it to.

See all problems of the 2010 Toyota RAV4 🔎.

20 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 09/10/2020

The gas tank is not able to be filled. Only 9 gallons can be entered. The drive range is only 400 mikes vs the 540 of the tank could be completely filled.

21 Other Fuel System Tank Assembly problem of the 2021 Toyota RAV4

Failure Date: 09/08/2020

With 4 miles left on hv range/dte, I filled my first full tank at costco. Pump read 10. 82 gallons. Now hv range is showing 544 miles. I got about 39. 9 mpg on first tank (without ev) which is in line with epa. But my real hv range from full to empty was only 10. 9 x 39. 5 = 430 miles. If you add ev miles of 42, then you get around 472 miles. Not 600. Their mpg claims are valid. But their gas tank/ range claims are clearly overstated. Real range is only 472. Not 600. Which is disappointing, you might go on a road trip with your family, and be stuck in middle of no where because their range claims were overstated. They marketed this to be close to being 600 mile range. When it can hardly go 472 when gas tank shows empty. Toyota is callous and negligent in resolving this issue so far. I was dissed by my Toyota dealer for the same issue with prius prime. Now Rav4 prime has he same issue, and I am hearing the same with Rav4 hybrid owners. You can only fill in 10+ gallons. Not 13 or 14 gallons as they falsely claim. Real range of your Rav4 prime/hybrid is only 470 miles not 600!! ## #vpic# 5 - VIN has errors in few positions; 14 - unable to provide information for all the characters in the VIN. #vpic#.

22 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 09/03/2020

The vehicle is hesitating, jerking when coming to a slow stop and when giving it gas. When putting gas in the car the pump automatically shut off. When I turned the car back on it showed that the tank was only 3/4 full. I put more gas again and the gas tank overflowed.

23 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 08/29/2020

When the empty light on the gas tank of my Toyota Rav4 hybrid le turns on, I am only able to fill the tank with 10. 5 gallons. Toyota specs states that the fuel tank should have a 14. 5 gallon capacity, and when the empty light turns on, there should be 2. 3 gallons left of fuel in the tank. I have communicated this to Toyota headquarters and to roseville Toyota in California, but they state that my VIN number is not within the list of affected cars, and they refuse to check on the issue to confirm my complaint and add my VIN to any program or support they might have.

24 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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.

25 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 08/01/2020

Car does not fill up with fuel to manufacturer specifications. Cannot get more than 10 gallons into 14. 5 gallon tank. Serious safety issue.

26 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 07/28/2020

Vehicle has a 14. 5 usg gas tank and gets approximately 40mpg as per the vehicle computer. The vehicle should have a range of approximately 560 miles. At 390 miles, the distance to empty display was 44 miles and the gas gauge needle was just above e. At the fill up the pump kicked off at 9. 6 gallons. When trying to add more gas, the punp kicked off again at 10. 1 gallons. The gas gauge reads full and the distance to empty reads 470 miles. I am either 4 gallons short of a full tank or the gauge reads empty when there is 4 gallons remaining. I have owned this car for 4 weeks. A service writer at the dealership denies any knowledge of the problem as there is no actual recall notice. Toyota is aware of the problem and has no remedy. Dealerships have been made aware through internal memos which are available online. The response from the dealership is to leave it for a day to be looked at. I realize there is no current fix, but dealerships should be documenting complaints.

27 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 07/06/2020

The fuel tank is rated at 14. 6 gal but the most I have been able to get out is 11 gal. The issue is consistent across every fueling periods and after taking it to the service center twice, the issue has not been fixed and the response has been that the fuel tank has no issues. I have shown the proofs to the service center and yet they deny claims.

28 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 07/01/2020

I purchased my brand new 2020 Rav4 hybrid on 7/1/2020 and was told the car is in perfect condition without any issue. Started with 2nd tank of gas fill up, I notice the meter reading is not correct. When I drove the car away on 7/1/2020, the reading show something like "520 miles to empty". With the 2nd tank fill up, the reading changed to "480 miles to empty". When comes to the 4th tank fill up, the read is now showing "410 miles to empty". Also, based on the car specifications, the tank size is 14. 5 gal, but I can only fill up around 10 gallons of gas, the tank would be full. I brought the car to the Toyota dealer where I purchased it today. I was just told they need to replace the fuel tank along with some other parts on the almost brand new car. This is not right. Toyota sold the car with major issue to me and without disclose the information at the time of the sale. The issue was long exist before I purchase the car after googled the issue online. They should have disclosed the faulty issue of the car at the time of the purchase.

29 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 06/25/2020

Fuel tank does not fill up 14. 5 gallons. It only fills up about 9-10 gallons of fuel. Mileage run on full tank is way way lesser than what is advertised.

30 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 06/21/2020

Fuel tank is advertised as 14. 5 gallons /580 miles per tank. Brand new vehicle off the lot only fills up to 8 gallons and gets 420miles per tank.

31 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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.

32 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 06/01/2020

Fueling ends prematurely. Topping off fuel tank can take as much as 2 more gals.

33 Other Fuel System Tank Assembly problem of the 2019 Toyota RAV4

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.

34 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 04/17/2020

When I fill my gas tank, it does not show full. I bought this SUV 4/17/2020. Also, burns through gas quickly. I seem to go get gas often as it quickly burns through half a tank, then stays there for a while then quickly down to 1/4 tank. I was sent from Toyota that they knew this is a problem but don't know how to fix. Now when I call them, they tell me they know nothing about this problem. Yet in their letter said do not top off and do not wait until the fuel light or will run out of gas.

35 Other Fuel System Tank Assembly problem of the 2020 Toyota RAV4

Failure Date: 04/06/2020

Fuel tank capacity when the car was bought new was 9. 3 gallons between low fuel light to refuel click at gas pump. After fuel tank capacity after fuel tank and pump replacement is 11. 3 gallons. This is between when the low fuel indication asserts to when refueling clicks at the gas station. This is still well below the advertised fuel capacity of 14. 5 gallons. A software reset was done, but the fuel capacity did not change. This causes us to refuel more often than expected since the advertised range of 500 miles on a tank of gas can not be achieved. Had we known of this issue when we bought the car, we would either not have bought the car or paid less. Toyota is still selling these cars without warning customers of the false advertisement.


Other Common Other Fuel System related problems of Toyota RAV4


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