Toyota RAV4 fuel smell problems

Filed Feb 8, 2026 · Body · MI

I am writing to formally report a significant structural failure regarding the power liftgate system on my 2020 Toyota RAV4 Hybrid XLE. Recently, the trunk began failing to close properly. Upon a detailed inspection, I discovered that the sheet metal surrounding the hinges has suffered catastrophic failure. The left-side hinge mounting point is severely fractured, and the right side is exhibiting clear stress cracks. This is not a case of "wear and tear." This is a structural failure where the force exerted by the factory power struts appears to have overpowered the vehicle's body structure, leading to metal fatigue and tearing. I would like to emphasize the following points regarding this case: Maintenance & Care: This vehicle has been maintained strictly according to Toyota’s recommended intervals and has been handled with the utmost care. There has been no external impact or misuse of the liftgate. Safety Risk: The inability to securely latch the trunk poses a severe safety hazard. I am concerned about the liftgate's stability at highway speeds and the potential for exhaust fumes to enter the cabin. Consequently, I no longer feel safe using this vehicle for my daily commute. Request for Action: Given that this appears to be a known issue within the 2019–2021 RAV4 production years, I am requesting that Toyota stand behind its reputation for quality and safety. I ask that Toyota cover the full cost of the structural repairs and the replacement of the affected hinges and struts. I trust that Toyota will treat this as a priority safety matter. I look forward to your prompt response regarding a diagnostic appointment and a resolution for these repairs. Sincerely, [XXX] VIN [XXX] Phone Number [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Dec 16, 2025 · Fuel system · CA

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.

Filed Sep 2, 2025 · Engine · MA · fire

The contact owned a 2014 Toyota RAV4. The contact stated that while driving at 30-40 MPH, while depressing the accelerator pedal, the vehicle stopped independently. No warning lights illuminated. The contact mentioned she noticed smoke and flames coming from the engine, and smoke started coming inside the vehicle. There was a fuel odor. present. The contact exited the vehicle and stood on the side of the road, and called 911. No injuries were sustained. No medical attention was required. A police report was filed. The fire department extinguished the fire. The vehicle was destroyed. The vehicle was towed to an unknown location. The vehicle was not repaired. The contact mentioned days prior to the battery warning light illuminating, and the battery was determined to be functioning as normal; therefore, the vehicle was resumed to be driven as normal. The manufacturer was not notified of the failure. The failure mileage was unknown

Filed May 27, 2024 · Body · NC

For about a year now the back hatch has not opened or closed properly. It sometimes stops just after the latch releases and will not go up. Sometimes it will not come down when you use the switch or it only comes down a few inches and stops. Recently the rear hatch is not aligned with the door opening and does not shut properly. When the rear hatch is closed, you can see that it is not seated in the opening. One side is still open. You can hear road noise from the rear hatch. I worry that exhaust fumes are getting in the rear hatch.

Filed Mar 8, 2024 · Fuel system · NM · crash

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.

Filed Feb 14, 2024 · Acceleration, Fuel system · FL

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

Filed Jan 24, 2024 · Fuel system · OH

On 11/15/23 I went to Byers Toyota Dealership and asked them to check my car due to the gas smell inside of the car when driven and outside of my car when parked for a longer period of time. The smell is coming from the rear. The car also has a very strong gas smell when the tank is open to pump gas. I did not notice any leaks. On the visit on 11/1523, they fixed the leaking evaporator according to your bulletin from May 2023 to alleviate the burning oil smell coming from my car’s HVAC heater. They also checked the fuel pump and told me that I have the correct one and it should function as designed. The service advisor told me that the gas smell is exhaust fumes and it is normal for Toyota type of engine. They did not have any explanation for the fuel smell when my car is parked. Since the smell was still present, I scheduled another appointment at the dealership on 1/3/24, they kept my car overnight but they were not able to duplicate any of my concerns. I did not contact Toyota Customer Care because they can be very unpleasant if the dealership cannot duplicate the problem.Â

Filed Nov 18, 2023 · Electrical, Engine · AZ

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.

Filed Jun 7, 2023 · Engine · CA

Engine repair light keeps coming on RAV4 HYBRID SMELL OF GASOLINE is present at times NOISES LIKE GRINDING OR SCRAPING from WHAT SOUNDS LIKE UNDER the CAR WHEN BRAKING AND akso WHEN accelerating

Filed May 29, 2023 · Fuel system · OH

When I started my car there was an overwhelming smell of gas. I immediately turned it off and looked under the hood at which time I realized a hose was melted. When the engine is on, gas sprays from the melted hose. I have had regular maintenance which was just 1 month ago. No warning lights were on. I purchased this vehicle new in September 2022. I am extremely concerned that this happened in a new vehicle which has had regular maintenance. Luckily it did not catch fire. I have contacted the dealership who sent a tow truck; however, the vehicle needs to have the engine on to put it in neutral and release the parking brake. The tow truck operator was therefore unable to tow it until the hose is replaced but dealership maintenance is unavailable today due to it being a holiday.