2021 Toyota RAV4 fuel system problems

Filed Mar 2, 2026 · Fuel system · 46,252 miles · NV

The contact owns a 2021 Toyota Rav4. The contact stated that while fueling the vehicle, the fuel tank failed to register the correct fuel level. The contact stated that the fuel warning light illuminated intermittently while driving and while the vehicle was parked. Additionally, the fuel gauge displayed inaccurate readings and eventually became inoperable, leaving the contact unaware of when the vehicle needed to be refueled. The vehicle was taken to the dealer for inspection. The dealer informed the contact that the fuel tank readings had failed, and the vehicle was supposed retain approximately 14.5 gallons of fuel; it would only accept approximately 11.5 gallons during testing. The contact was further informed that the fuel tank and fuel reader had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the federal safety agency Hotline for further assistance. The approximate failure mileage was 46,252.

Filed Sep 11, 2025 · Electrical, Fuel system · MA

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.

Filed Jul 9, 2025 · Driver assistance, Engine · TX

Coolant bypass valve problem with several rav4s. My car is unusable and I need it to work.

Filed May 20, 2025 · Electrical, Engine · IN

Steering power low message appears and engine completely stops.

Filed Apr 8, 2025 · Electrical, Fuel system · ME

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.

Filed Mar 20, 2025 · Electrical, Fuel system · CA

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 federal safety agency to: 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.

Filed Apr 6, 2024 · Fuel system · AZ

Fuel pressure line leaking gas

Filed Feb 11, 2024 · Fuel system · CA

My 2021 Rav 4 Premium I Bought new @ 84 miles from Toyota Town of Stockton,Ca I noticed Once in November 2023 Gas gauge not read gas level properly. December at least twice I noticed issue progress from gas Gauge reading inconsistence to Gas tank failure to fill up or failure to Allow gas. [XXX] I am at Gas station, while trying to fill up Based on my tank level at half a tank My gas tank did not allow gas in I got Push back. I retried 2 more times And gas went in slowly but gas gauge after still read half tank. Local Toyota [XXX] Said they cannot duplicate problem. I cannot rely on accuracy of gauge Or tank I have had same problem gas gauge failure read & tank no accept gas issues In previous Toyota’s bought new. 2008 PRIUS Prius safety issue found by Local Toyota who switched out Gas gauge & possibly gas tank but Issue continued never could be fixed. Reported to Toyota corporation, [XXX] issue started Until I got ride of it 2021. When Prius Deceleration happened for first time On my way to Toyota. I was drove from work I could guide steering but power dropped, deceleration stayed active. So thankful no accident. Toyota Tech said I had gas. They did whatever problem Paused but came back! I HAD TO GET RIDE OF PRIUS SAFETY AT STAKE! [XXX] The Prius decelerated hazards On Prius system on a red Triangle On my computer saying need gas But, it had plenty gas and Technician Found it had gas, that was not cause Of problem. 2020 Hybrid RAV 4 delivered by Roseville Toyota of CA When they delivered SUV on less than full tank to my home. Waited 2 days for insurance Fully ensure car. 3rd day first day I Drove car and I went to gas station Twice to try fill up, but Gas gauge no respond to input of gas In tank. I did a video address issues With Roseville Toyota and Toyota Corporation. I returned car, I did Not know Toyota Corporation Rejected Contract until I spoke to Roseville Toyota in person. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Apr 5, 2023 · Airbags, Driver assistance · VT · crash · fire

While accelerating ~6ft from a complete stop, a minor collision occurred affecting the front right headlight. The air-bags did not activate and the engine compartment was immediately on fire. Within ~1minute, the fire had spread to and completely engulfed the passenger compartment. The contents were immediately destroyed. The speed with which the fire spread through the vehicle was a significant risk to my life and the motorists around me. There were no warning lights on the dashboard prior to the incident, and the car had never before experienced an accident. Witnesses and firefighters estimated that any fire barrier between the engine and passenger compartments had failed, and that a fire of that severity from such a minor accident indicated some fault with the vehicle. The vehicle was an immediate total loss as inspected by our insurer.

Filed Feb 21, 2023 · Fuel system · NH

I purchased car in 12/20. The car has a 14.5 gal sized tank, and gets avg 42 mpg -calculated by miles driven to empty divided by gas pumped when empty- as well as on dashboard display. Since purchase the car registers empty 150 or more miles sooner than the 560 dashboard estimate and than 14.5*42 mpg. I am only able to fill less than 11 gallons when the fuel Guage reads empty with less than 20 miles remaining. The service dept assures me the car is able to drive 560 on a full tank, as the fuel Guage and miles-to-empty ignore a "buffer " of several gallons in the tank. It is unsafe to drive over 150 miles with the car registering no miles remaining. It is unsafe to plan a trip based on dashboard or tank size/gallons mileage, where I could run out of gas in an unsafe region.