2019 TOYOTA RAV4 Fuelpropulsion System Problems

Vehicle consistently accepts only approximately 9–10 gallons of fuel when the fuel gauge indicates empty, resulting in significantly reduced driving range. Issue has been widely reported by other Toyota RAV4 Hybrid owners and appears related to fuel tank design. Manufacturer declined assistance and referred responsibility to selling dealer despite known complaints.

This is another complaint with the same issue. Got gas on January 1, 2026, the truck did not how any indication that it was going to have any problems. Engine shut down and wouldn’t turn back on. This has happened twice after getting gas, no dealership knows the problem. This is casing me stress and putting myself and family in danger. Considering it stops out of no where

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.

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...

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.

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...

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.

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...

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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...

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 .

My RAV4 does not hold a full tank of gas. It only allows half a tank get full of gasoline. Toyota says they don't know how to fix, as well as two other shops I have brought it to. There are no engine messages or any other signs of issues. Gas will gush out of the tank when filling up if I do not stop at half way.

"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.

The engine maintenance required turned on at55k miles for the coolant bypass. After trying to get it repaired they had 500 on back order. Thousands of Rav 4’s are experiencing this with over $800 quote to repair , this cannot just be a basic issue this is bigger.

The vehicle does not get anywhere near the advertised fuel tank capacity. The fuel tank size IS 14.5, but when fueling it gets >10. Causing the vehicle to get nowhere near the maximum mileage until empty.

Car is shaking when turned on. Will stall if car is not shifted to gear sometimes. When AC is on, car will jump rpm. car acceleration is weak and will jump to 5-6k rpm. car also smells burnt sometimes when driving. car also smells like gasoline sometimes. car does not hold proper amount of gasoline.

I have 2019 Toyota RAV4. 69,000 miles. I had issue this week when I was driving and park. The gas given by it self after I park the vehicle. and today all of the sudden stop on the road. The dash board shows me EPS light, Battery sign.

As I opened up the fuel door - a spring popped out - after I finished fueling- I tried to reopen the fuel door but could not - this can strand a driver when gas gets low as unable to refill the gas tank due to inability to open the door

The fuel system will not fill up the full tank. When the tank is half full it signals for the pump to stop and that is all that will go in the tank.

Unintended acceleration.

I am not able to fill up the fuel tank to capacity. 8 gallons is all I. An vet in the tank. The tank is not full. The gauges show it’s about at the half way mark.

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The engine on my Rav4 suddenly stopped without any notification while I was driving it on the freeway. I could have been severely injured from the risk of being rear ended by vehicles behind me. I have experienced this twice now, and both times, I have been on a busy highway in the middle of rush hour traffic. While driving, the engine would start sputtering and the vehicle will jolt and shake, eventually causing a warning message to appear that says power steering low, engine shutting off, place vehicle in Park. Then, when I turn the engine off, and try to restart it, it would flash a message that read Not ready to drive. After towing the vehicle to a service department, the vehicle would start up like normal, and the techs could not get vehicle to duplicate the issue. No codes would come up when they place it on...

Hybrid system malfunction. Repairs include replacement of motor cable #2 and frame wire. Advanced Corrosion was the explanation. Not covered under warranty (either 3yr/36K or platinum addt’l plan). Problem occurred at 36,366 miles (300+ miles just over standard warranty?) In the midst of delayed communicating with Toyota with no response after 3 days. Was told to reference TSB T-TT-0630-20. After researching, this problem is frequently referenced as being an issue. Should just be a recall at this point.

Engine maintenance light came on after a routine oil change. I took it to a toyota dealer, they said that it has something to do with the coolant system. The problem is ongoing with several toyota models, including rav4, Tacoma, Tundra, Camry, Sienna models 2018-2022. The problem is that the car can suddenly overheat and shut down on a busy highway, which is very Dangerous. Someone, can get killed, if this is not addressed. I don't know why there is not a recall already. The government should definitely get involved.

Fuel pump was replaced in May 2020 under recall. Recalled part had 12 month warranty. Rav4 was purchased used in May 2022 and in June, engine started stuttering. Contacted Toyota Field Reps at local dealership and they reset codes and suggested running different and better gas. A case was opened. In July, when filling up car, the car would not start at the pump. The car had to be towed on Sunday. Toyota Field Reps made aware that car would crank after banging on the fuel tank. A service call was placed again and before we could get it to the dealership on Thursday, when the car was filled up again at a different gas station, it would not start at the pump again. It was towed a second time to the dealership and Toyota did multiple tests to determine the fuel pump and hose over the saddle tank needed...

Fuel pump malfunction. Stalling out with no warning or no previous issues

My fuel range went from 400 miles to 330 in a months time. I already had the recall fixed. I am concerned that the replacement fuel system is bad.

Took my 2019 RAV4 to Toyota of Orange. Like couple months ago for fuel pump recal but my vehicle stalls when driving on freeway or streets. Looses speed for 4 seconds and its scary reported issues to Toyota of Orange and they don’t fixed anything they only want to sell. They offer me services I don’t need for my vehicle. Got 2021 RAV4 rental from Enterprise and that one work just find no problems had it for about a week. If could get another another dealer that will be great.

gas meter is incorrect car is suppose to have 14.5 gallons fuel tank and im only able to out in 9 gallons. gas range meter is incorrect reads wrong range of mileage... need to be recall many people are complaining about this issue toyota should correct it...

Engine stalled on a highway going 65 mph in cruise control. I had 1/4 full fuel tank. just before the engine stopped working I read information on my dashboard I have to stop the car in .5 miles, than .3 miles and engine stalled within seconds. I was able to pull over with dead engine. I shut down the car using key (I have a mechanical key for ignition) and car started with a message 'hybrid system malfunction. output power reduced . visit your dealer." I visited local mechanic who read the codes and instructed its a faulty fuel pump. I filled the car with more gas and drove couple of miles with reduced power. I left the car for 36 hours and it started to run ok by itself. dealer replaced fuel pump and now it works fine. The day of incident I was able to smell gas around...

When filling the fuel tank when full fuel spills out until the pump handle finally shuts off. Estimated spillage is about 1/2 to 1 cup of fuel. This has happened more than 6 times

Unknown component or system While driving on the Interstate during rush hour, traveling 60 miles an hour, another vehicle along side us entered our lane and we had to avoid a collision by aggressive braking and steering. Following this maneuver, our vehicle immediately shut down. An 18 wheel barely missed crashing into our rear. It took us approximately 1 minute to realize we needed to put the car in park, step on the brake, and push the ignition button to restart the vehicle.

Case number started at Toyota Customer service: 210701002045 Requested an unacceptable time to answer of 8 weeks. There was a recall for this vehicle. I wasnt notified and the recall also doesnt show in any website (Not Toyota not in the goverment one). I went on a trip thousands mile aways from home, I was up in the montains, the car got broken in a very bad place where I had to spend almost $2,000 dollars due to Towing, meal and hotel expenses (as the dealer was closed on a weekend). I am trying to solve this with Toyota but they say I have to wait 8 weeks to start looking at my case. It is unacceptable . I need a reimbursement ASAP.

MY VEHICLE IS STALLING WHEN AT LOW SPEED AND SOMETIMES HIGH SPEED. IT FAILS TO ACCELERATE. EVERY TIME I CONTACT MY SERVICE PROVIDER THEY PUSH BACK MY SERVICE ANOTHER MONTH.

TOYOTA HAS NOT PROVIDED THE PARTS TO REMEDY A KNOWN RECALL. MANUFACTURER RECALL NUMBER20TA02 NHTSA RECALL NUMBER20V682 THE DEALERSHIP HAS HAD MY LEASED VEHICLE FOR OVER 5 MONTHS AND HAS YET TO PROVIDE A DATE THAT THEY WILL HAVE IT REPAIRED AND DRIVABLE. WHILE THEY HAVE PROVIDED ME A LOANER FROM A SECOND RATE RENTAL COMPANY, I AM EXTREMELY FRUSTRATED THAT I AM NOT ABLE TO DRIVE THE CAR I AM REQUIRED TO MAKE PAYMENTS ON. DUE TO MY AGE, THE RENTAL COMPANY CHARGES MORE FOR A COMPARABLE VEHICLE, SO I AM FORCED TO DRIVE A GREATLY INFERIOR CAR TO THAT WHICH I AM PAYING FOR. ADDITIONALLY, AT THE END OF MY LEASE, THE VEHICLE WILL HAVE SIGNIFICANTLY FEWER MILES THAT MY LEASE AGREEMENT ALLOWS (SINCE IT HAS BEEN PARKED ON THEIR LOT FOR SO LONG, WHICH WILL SIGNIFICANTLY INCREASE THE VALUE OF THE VEHICLE FOR THEIR RESALE. I HAVE...

AFTER RECEIVING THE RAV4HYBRID FUEL TANK FIX FROM TOYOTA IN MARCH OF 2021, MY VEHICLE STILL ONLY HAS A FUEL CAPACITY OF 12.5 GALS. THE DEALERSHIP STATES THIS IS BY DESIGN TO ALLOW ROOM FOR SPLASH BACK. 12.5GALS DOES NOT ALLOW FOR THE TOYOTA ADVERTISED RANGE OF 550MILES PER TANK. I AM GETTING ~470MILES PER TANK, 80 MILES SHORT OF THE TOYOTA ADVERTISED. THE FIX FROM TOYOTA TO REPLACE THE FUEL TANK AND ASCENDING UNIT HAD NO CHANGE TO MY FUEL GAUGE READING, DISTANCE TO EMPTY OR FUEL FILLING CAPACITY. I CONTACTED THE DEALER AND TOOK MY VEHICLE BACK IN AGAIN, THE INFORMED ME I WILL NEVER BE ABLE TO PUT MORE THEN 12.5 GALS OF FUEL IN MY VEHICLE AND WILL ONLY GET ~470MILES PER TANK; THEY WERE NOT ABLE TO PROVIDE AN ANSWER TO THE CONTRADICTION OF WHAT THEY WERE ADVERTISING THE RANGE OF MY VEHICLE SHOWN AT...

RECEIVED NOTIFICATION OF RECALL FROM TOYOTA IN JANUARY OF 2021. NOTICE STATED THAT PART TO REPAIR CONDITION WOULD BE AVAILABLE IN LATE MARCH. LATEST INFORMATION IS THAT PART WILL NOW BE AVAILABLE IN LATE APRIL. DEALERSHIP HAS PROVIDED FREE LOANER VEHICLE, BUT WE WANT OUR RAV4 BACK.

UNABLE TO FILL GAS TANK SO THAT THE GAUGE REFLECTS "FULL". TANK ONLY SHOWS ABOUT 7/8 OF A TANK.

CAR STALLS WHEN ACCELIATOR IS DEPRESSED WHILE GOING FOWARD BEFORE COMING TO A COMPLETE STOP

RECALL FOR A FUEL PUMP AND TOYOTA STILL DOES NOT HAVE A FIX AFTER 4 MONTHS

STILL WAITING FOR TOYOTA TO REMEDY A RECALL ISSUED OCT 28 2020. THEY SAY THERE IS NO FIX YET. THIS HAS BEEN TOO LONG TO DRIVE WITH THE RISK OF MY VEHICLE STALLING AND POTENTIALLY CAUSING AN ACCIDENT.

I RECEIVED A RECALL NOTICE MONTHS AGO AND THE RECALL HAS YET TO BE SATISFIED ALL THE WHILE MY TODDLER GRANDCHILD IS IN THIS VEHICLE REGULARLY. MY BIGGEST ISSUE IS THE SAFETY OF A VEHICLE THAT MAY STILL AT HWY SPEEDS AND RESULT IN A CRASH

DIDNT FILL UP GAS TANK AND BRAKE PRESSURE IS LOW. ITS TAKE TOO MUCH SPACE TO STOP.

ABOUT TWO MONTHS AGO I PURCHASED MY FIRST VEHICLE EVER, IT WAS A USED CAR, AS A NEW CAR OWNER I WAS SUPER EXCITED FOR MY FIRST CAR,DRIVING OUT THE DEALERSHIP! BUT LATER ON FINDING OUT THAT THE CAR HAD SOME SORT OF RECALL ON IT ,NOT KNOWING WHAT THIS MEANT, I STARTED DOING MY OWN RESEARCH AND FOUND OUT THAT THIS WAS A SAFETY HAZARD FOR ME AND OTHERS ON THE ROAD! SAFETY RECALL 20TA02

CAR LOST POWER TWICE, GOING UP A STEEP GRADE. 'HYBRID SYSTEM MALFUNCTION' WARNING CAME ON THE SCREEN, GAS PEDAL DID NOT WORK AT ALL. I WAS UNABLE TO GET TO A SAFE PLACE WITH CHILDREN IN THE CAR, BOTH TIMES ON THE INTERSTATE. DRIVING UP A STEEP MOUNTAIN, ABOUT 50F WEATHER.

FUEL TANK DOES NOT FILL UP TO MAXIMUM AND LEAVES ABOUT 3-4 GALLONS SHORT. THIS HAS BEEN OCCURRING SINCE LATE 2019. I'VE BROUGHT THIS US TO THE DEALERSHIP SEVERAL TIMES, BUT NOTHING HAS BEEN DONE.

FUEL TANK DOES NOT FILL UP ALL THE WAY. MISSING ABOUT 3 GALLONS.