RAV4 Hybrid Fuel Tank Issue Fixed By Toyota Program - UPDATE! Class Action Settlement

Took this in on Friday. Had it done Saturday. First one for this dealership, which is a huge dealership. Paperwork shows that tank was replaced. The notice says to make sure tank is filled to auto shutoff before bringing it in, This ended up being a problem. When I picked up car, it reeked of gas, inside and out. Foolishly drove it home thinking incidental gas spillage would dissipate. Five hours later odor had migrated from garage into house. Took it back to dealer. They admitted gas had spilled all over because tank was so full (they hadn't read the notice). So, if you're having this taken care of, ignore the instruction to fill the tank. Let the dealer fill it if they want to

We've had the same problem with our Rav4 Hybrid. I've run it down to 25 miles to empty and not been able to put more than 9 gallons in the tank. The local dealer did replace tank last summer but unlike Rob it did not fixed the problem. I've not received a letter from Toyota yet. I've called the local dealer and currently waiting for a call back.

Before keeping your attitude about your tank not filling when the gauge says "E", note this. For years, in my case back to 1989, Toyota tanks and gauges have had their full capacity and their "gauge" readings. Upon careful attention to the re-filling of my tanks, I deduced that the yellow warning light comes on with a minimum of 2.5 gallons, and often 3 gallons and a touch more in the tank. The red light, usually when the needle/indicator hits E, comes on and there is a guaranteed 1 gallon in the tank. While you can thank Toyota for the "safety" factor, and the fake info about your gas quantity, get to know your car a little better. Toyota is treating the car buying public as if they don't know and don't care about how their cars operate, hence the idiot lights on the gauge that mislead. I have had to re-assure my wife, noted for her OCD tendencies, dozens of times that she was not going to run out of gas before she made it to a filling station. All because a light comes on when there is still 90-100 miles of range left. And, this is when our cars were getting only 27-32 mpg. We currently own Toyotas that get 32-38 mpg, and the lights still come on with 2.5-3 gallons left in the tank.

My 2019 Rav4 XSE was fixed in December. Fill-ups went from 9 gallons to 11.5 when the low gas light comes on (<20 miles range). I'm getting 360-390 miles per tank. My MPG has decreased to 30 MPG hwy and 34 mpg city. My driving habits are similar to pre-fix. My MPG is now about what the non-hybrid is. I don't call this a fix. What happened to 38/41 MPG?

Yes, after 400 days out of service, for a tank which the dealer could only get TWO gallons in, mine had this fix. Like others here are reporting, it's STILL not fixed. In the last two fill-ups (done with a system-reported 5-10 miles of range left, mine will take an average of close to 10 gallons, and since it's averaging 29 mpg (NOT the 38-40 advertised) it means I now have a range of 305 miles not the 580 I was told this would get. Just in the shop today and the vehicle returned to me with an acknowledgement they can't do better. So no, for many of us, Toyota has not fixed this issue.

I'm pleased that Toyota acknowledged the RAV 4 fuel tank a few months after it was first reported in spring of 2019. And that they are fixing the problem at no cost. I am not so happy that our dealer in Ontario Canada can't be bothered to keep the fuel tanks in stock, so what should be a one-day job actually drags on over two or three days. And I don't think it was appropriate for Toyota's Ontario letter to owners threatened to make them pay for the "diagnosis visit" if their staff concluded that my car didn't really have the problem. Finally there remains the mystery of what actually causes the problem. Toyota must know the cause, so why haven't they publicly revealed it? It seems at least possible that they still don't fully understand it. If they did fully understand it, you would think that they could tell whether a specific car has the problem - based on date and location of manufacture.

Not happy so far after the fix with 2 fillups. I have a 2020 Xle and the tank only took 10.8 gallons after fillup and shows full but it always did unlike many 2019 owners. The estimated range is at 465 and I want to see this around 544+ like the first tank of gas that came with the car and what was advertised. I am getting only 34mpg in town and have never been close to 40 as advertised. Going to call Toyota cuatomer center tomorrow.

I had the fuel tank replaced last week on my 2019 RAV 4 Hybrid and was told to run the fuel down to around a quarter tank before I brought it in which I did. It took me a while to do this because of the great fuel mileage. The dealership had my car ready in about four hours. My first gas fill up using the automatic shut off worked as advertised the tank filled up quickly and the fuel gauge read a little more than full.

What years? I have a 2017 Toyota RAV4 Hybrid
Thank you

I have a 2019Rav4 hybrid. I had the same issue and my dealer replaced the sending unit and the gas tank back in October 2019. This issue has now recurred. While I'm interested in contacting my dealership for another "fix", I'm skeptical that this is the real solution.

Please include the trip estimated miles if yiu post here that would be a great help. I'm talking with Toyota cuatomer care asking what the next steps are to get back to over 500 estimated miles. The agent said first that all depends on your driving and that might not be over 500..

After seeing this article (I did not receive a letter from Toyota) I called my dealer and made an appointment for today at 10:30 AM. I was skeptical at first as they told me to have a seat and they would “look into it.” After about an hour they told me it would take all day to replace the tank and sensor. They had the parts so they provided a courtesy car and said they would call when it was finished. At 6 PM they called and I picked up my 2019 RAV4 with a full tank of gas at no charge. I’m very happy with Erdman Toyota here in Cocoa FL. Thanks for the article. I might have missed out without reading it here.

I am considering buying a 2021 Toyota Rav4 Hybrid Limited and was wondering if anyone knows whether this problem has been fixed with the 2021 Rav4 Hybrid model? Thanks.

I have a 2020 RAV4 Hybrid, I drove until it told me I 3 miles left. Filled the tank and it filled up to 11.5 gallons (I average 35 m/g). The gauge meter was still hovering above the E though. Has anyone attempted to see how far the meter can go down and ignore the estimated miles?

My Toyota dealer replaced the fuel tank on my 2019 Rav4 Hybrid two weeks ago. The good is that I can now fill the tank with no problem. The bad is now my fuel gauge is acting crazy. The gauge does not move after filling the tank until I drive 10 miles down the road when it suddenly goes moves to full. When the gauge reads 3/4 and 1/2 a tank the needle moves back to full. This is happening while the vehicle is moving. I've take it back but still having similar problems. Has anyone else had this problem?