2019 RAV4 Hybrid advertised ~550+ mile range, but not true for mine?

Yes I have the same issue, dealer looked at it and they are aware.

Heard the phrase "your mileage may vary"? How many gallons of gas are left in the tank when you fill up? If you are leaving 3 gallons unused there is your 100 miles not that I recommend running it low on gas as this can ruin your fuel pump.

I would be understanding of anywhere near 500. I saw another ad and it said 580 for a full tank. The mile range displayed after I fill up is 390-430 miles.. I usually fill up between low and 1/2 tank. I contacted Toyota support and they agreed there seems to be an issue and suggested I talk to my dealership. I will be going this week. @GuruHYM6R please let me know if your dealer gets back to you with any info!

Actually, I find that the tank actually is difficult to fill. The auto stop kicks in way too early. If I stop it there, my mileage indicator is about 400. But, if I pull nozzle out a little and SLOWLY very SLOWLY, I can get another 1.6 gallons in. Then my mileage indicator says 557 miles. I also find it says I’m at 60 miles left when I still have 1/4 tank on the gas gauge.

I have just completed a 450 mile round trip on what I thought was a full tank of gas, (I did the annoying thing of trying to top it up). At around 30 miles left till empty the low fuel warning came on (so less than a gallon if you believe the avg mpg of around 39). and I went to refuel. Try as I may I could not add any more than 11.9 gals. I'll agree that the trip was completed at an average mpg of around 39 (it was highway for the most part) but I'm not sure if I could ever get 14.5 gallons into the tank

Topping off is a good way to cause expensive damage to your car. At the very least it wastes money and most of that gas goes right back into the gas stations underground tank.

If your car took 11.9 gallons and the tank is 14.5 that means it probably had 2.6 gallons left in the tank. Running it down to empty is a good way to ruin your fuel pump!

If you are getting the claimed 41 mpg city fuel economy it would take 13.4 gallons to go 550 miles which would leave you 1.1 gallon in the tank. At 38 mpg highway you would run out of gas at 550 miles out on the highway. I do not recommend going that low on gas because the fuel pump is gas cooled and when the tank is that low the fuel pump can overheat, burn up and stop working.

How then do you explain how I have 2.6 gals left but only 26 miles of range showing when I refilled? The total trip amounted to 476 if I believe the gauge and this from a supposedly full tank. The math doesn't add up. The tank obviously didn't have 14.5 gallons in it to begin the trip and it seems it is very difficult to fill it judging from the other customers' comments.

I doubt the computer is set to run the tank down to zero. If it did then people would be complaining about running out of gas. The range claims they make are mathematically correct. Leaving a 2 gallon reserve is wise on their part.

Incidentally I calculated your fuel economy. 450 miles using 11.9 gallons of gas is 37.9 MPG which matches their highway claim of 38. You are getting what you paid for.

It doesn't make sense that Toyota would leave a 2 gallon reserve (outside of their mile range) when no other cars do that. Generally for every car, the low gas light turns on when you have around a couple gallons left, and it's the driver's responsibility to fill in the gas before you run out. No one should be complaining about running out of gas when the warning light's been going off for miles. Additionally, Toyota shouldn't be advertising ~580 miles/full tank if on average, real world car owners are only getting <450. Of course, advertisements may be slightly exaggerated and measured in the most ideal conditions, but 100+ miles is quite excessive. All in all, I got my car inspected by my Toyota dealership, and they agreed something seems to be off with the mile range. They encouraged me to file a complaint with corporate Toyota for additional testing, so I will be doing that soon.

GuruS3H54: Please let me know if you get a response from them. Most of the answers on this forum seem to be of very little use; stating the obvious, ignoring the math or simply unfounded speculation.

I have the same problem! When I fill up until the fuel nozzle "pop's" I can only fill under 10 gal and this is with less then 30 miles left and the low gas warning light on. If the tank fits 14.5 gal it means I'm never using 5 gallons!! That's ridiculous! Also bought the car for the range, but can never get more than 400miles and that's going all the way to under 30miles.

I have the same problem. The gas pump always clicks off at 3/4 full. The dealership just told me Toyota designed it this way to avoid overfilling and damaging the charcoal canister.

That's funny - my dealership told me to "just top it off"! After I brought in my car to complain they drove off to get gas "to test" and came back with the control showing 580 miles!!! When I asked how they got that, they said - oh we always top off! Someone doesn't have their story straight.

It is a legitimate problem that Toyota continues to ignore and claim ignorance on. There is a long thread on this on Rav4World Forums with over 900 postings as of today.

Here is the link: https://www.rav4world.com/threads/difficulty-with-getting-fuel-tank-full.298909/page-46

Have a case opened with Toyota for same issues (early clicking off of gas pump, only getting 10-11 gals in on refill, etc.). Toyota rep called me yesterday (8/21) and said the issue is now recognized by Toyota and they will be working on a solution. Told me that I would be notified by local dealer or her whenever a solution is found. She told me to call back every few weeks to check on status of finding a solution.

This is a WIDESPREAD issue with the 2019 Rav4 Hybrid. Mine has 6,000 miles and will not fill up past 3/4. Dealership is unable to fill it too. They serviced it 3 times and finally called main Toyota. Toyota finally acknowledged that they are aware of this problem but there is currently no fix. So basically we’re stuck with vehicles that are incapable of obtaining the maximum mileage range because they will not fill up to Full.

My Toyota case mgr called ystrdy, 8/28, and said 1st attempted fix is to replace gas tank; unfortunately tanks are on back order. Asked what I thought were 2 key questions - if the non hybrid Rav has no problem, are they looking at the differences in those 2 models gas systems (hybrid vs non-hybrid)? Were the hybrids with the issue all made in same area (Japan, USA, etc.)? This could pin down a supply component. Just have to wait now. If you have not called Toyota and reported issue, call 800-331-4331

I took mine in today for 5k service after having them not be able to figure out the problem a couple of months ago when I took it in. They say now they have a fix and will call me when the parts are in to bring it back in. We’ll see. I’m relieved to know I’m not the only one. I got the car pretty early—in April, so when I first started googling the problem nothing was coming up.

I guess we all have to wait until Toyota confirm a fix.

Toyota has confirmed a fix as of last week. They will need to replace the entire gas tank. My dealer has already done one such replacement for this issue. There are 4 parts needed. I was told it might be a few weeks until all the parts arrive. If you have this issue you should call your dealer asap so you don’t have to wait forever for parts.

If a fix has been confirmed by Toyota, is anyone aware of a Technical Service Bulletin (TSB) that has been issued by Toyota for the fueling problem fix?

Talk to the main Toyota today they do not have a fix the engineers thought that by replacing the fuel tank that that fix the issue but less than 30 days later those vehicles started to fail again. The engineers met again this morning and are starting from square one to identify what is causing this issue

I called my service advisor and they said that the fuel tank replacement was the first fix and that didn’t work but they now have the second fix that does work. Seems like someone has incorrect info but it’s not clear who.

I took my Rav4 Hybrid in today. My gas gauge is not working right and it is very hard to gas up. Pump keeps stopping. Shop manager said they know of the problem and currently have no fix. My 6th Toyota. Not happy with this at all. My fault for buying early....

I just took my Rav4 XSE Hybrid to the dealer today. They have told me that I will only be able to fill my tank up to 11 gallons and not 14.5 (the actual size of the tank). So the advertised 600 miles to tank is only theoretical from what the service department is telling me and I should expect to get 400-450 miles to a tank (which in their eyes is still 40 mpg) but in my mind I have to stop to fill up more frequently. Very disappointing.........

1.5 month old Limited Hybrid here with the same issue. Opened a case with Toyota yesterday. Talked to case manager today. Toyota acknowledged that the issue is not the gas gauge, per sé, but the tank actually not filling completely. I was also told told that Toyota engineering: 1. Is working “diligently and around-the-clock” to derive a fix. 2. Does not provide incremental progress updates. The next/only update from engineering will be that a fix has been found. I’m sure they’ll figure it out, but I do recommend being familiar with your state’s lemon law to make sure you have your bases/contingencies covered.

I filed formal complaints with NTSA and Toyota around 1500 miles. Waited to take my XSE in until 5K service a couple of weeks ago. I’d taken screen shots of dash display before and after “fills” and of pump displays and submitted them to the service advisor. They tried a software fix which only artificially showed a F display, but the tech noted that did not alter fact tank would click off at under 10 gallons. Even when they forced more, couldn’t get it full. After 3 days I got it back as they ordered parts. Had to wait a week. Early this week they replaced the parts shown on the invoice screen shot. I again got a full tank of gas courtesy of Toyota. It LOOKS promising as gauge slightly over full and never before seen DTE read 550 at pick up. I’m cautiously optimistic. It will take a few fill ups for me to believe the fix is real! Service advisor and tech feel bladder inside the original tank caused too much back pressure to allow a fill.

XLE bought on Aug 30. I realized it has the same problem for the 2 refills. Will call headquarter and dealer to create case number.

I talk to my dealer often. Toyota has no fix. They claim some do not have this issue but they are still making and selling cars that have this issue. I filed a complaint with the Nhtsa. I recommend doing this as the more they get may force a recall.

When the gas warning light comes on, I can only pump at best 8.5 gal of gas. When the pointer reaches the empty line, ignoring all warnings, I can only pump 11 gal. Neither Toyota, not my local dealer ship had any answers. Something is clearly not right.

No it is not right. Now you can bypass that by turning on accessory button where you can see gas gauge. When the pump shuts off because the car “thinks it’s full” you can hand pump another 1-2 gallons and watch the gauge go up to the Full mark where it is supposed to be on any other car. Still NOT acceptable to have to do this on new car. My 2000 Honda Civic doesn’t have this issue and fills up full even at 19 years old!

Had my 2019 XLE serviced yesterday and had same parts replaced as referenced by Susanjack earlier. Good news was that I pumped 10+ gals in and gauge read F. Was never able to get more than 7 in before and never got to F. Not so good news was that DTE only went to 494. Will have to fill up a few times to see if issue is fixed. MichaelS219

I have only been able to drive my 2019 limited hybrid 411 miles at most, which was today. When I “filled” it to capacity, it was just under 10 gallons. I have never put in more than this amount (the gas light was on). It does not hold 14.5 gallons.

Would "susanjack" be as kind to update us if the "fix" is still working/ Thank you - markbusdriver -

I went to the dealer yesterday thinking it was a problem with the gauge. I bought mine about about 6 weeks ago and have only filled up twice. Both times I ran the fuel down to where there was probably only a couple of gallons left, but both times put in only 8.5-9 gallons rather than what should have been around 11 or 12 gallons. They told me it is a problem with the tank not the gauge. I don’t understand exactly, but this is what I was told: there is something that causes the tank to shrink as fuel is consumed. Apparently whatever that thing is it is not allowing the tank to return to its normal configuration thus leaving it as a 10 gallon tank vs the specs of 14.2 gallons. I was told that replacing the tank would not resolve the problem (it’s an “engineering” problem) and that Toyota was aware of the problem and is working on a solution. I find it very interesting that people are getting different messages from dealers. I hope Toyota is monitoring this site as this issue and the confusing answers people are getting is really frustrating and hurting their reputation. Like everyone else one of the main reasons I bought this vehicle is the estimated driving range and we aren’t getting anywhere close to that.

I bought my Rav4 HV May 11, 2019. I have never been able to refuel it to full without having to coax 2-3 more gallons into it after the pump auto shuts off at 3/4 full. The gas gauge is accurate. I have been to the dealer three times about this. I have talked to technical assistance at Toyota USA. So Toyota has been notified and there is an open technical case on my vehicle. As yet, Toyota Engineering has no fix/repair for dealers to address the problem. Also there is no interim solution of a formula for consumers to calculate remaining capacity to full after auto shut off based on miles driven and mpg since previous refueling. There is no recall, at least not for my VIN (https://vinrcl.safercar.gov/vin/vinLookup). It has been 4 months since I began complaining and my technical case was opened. I have submitted a complaint to https://www-odi.nhtsa.dot.gov/VehicleComplaint/ I spoke with consumer protection at my AG's office (Massachusetts). If I understand correctly, my next step is to find out if my case is eligible for arbitration before pursuing redress under the lemon law for new cars with a defect if under 15k miles on odometer or 1 year since purchase, whichever is first, plus 3 trips to the dealer for repair without success. If not eligible for arbitration, I can write Toyota a 7 day last chance to repair letter, cc-ing the dealer. Under the lemon law an owner is entitled to a refund or replacement.

We are doing a lemon law repurchase through Toyota and should have our check in next two weeks. We will be purchasing a gas model this time if we choose to stick with Toyota.

Did the lemon law repurchase happen through arbitration with Toyota? In what state/country?

Idaho. And everyone just needs to stay firm and keep calling Toyota and let them know that they need to repurchase since they sold us defective cars.

I dove my rav4 hybrid nine thousand mile + to close to empty three times never Abel to get more then nine gallons in tank

I got the same issue that could not fill up to 14.5 gallons. I brought my car to the services and complaint twice, but no fix for this gas tank so far. I suggest everyone should file a complaint on this page in below link. https://www-odi.nhtsa.dot.gov/VehicleComplaint/ This is the negligent misrepresentation of a brand name. Hope this case is not the same as Volkswagen emission recall case. You can google this case. It is a big one in the US car history. https://en.wikipedia.org/wiki/Volkswagen_emissions_scandal

Took mine into the dealer yesterday for 5000 mile service. I have never been able to put more than 9 gallons in even when the vehicle said I had only 20 miles of range left. They told me there is no fix at this time. No promise to ever fix it. No commitment to report to me when a fix is found. Wasted 7 hours at the dealership when I suspect they knew what they were going to tell me before I came in. Bummed.

I'm starting the whole lemon law buyback process too. Bought my XSE in early September and it has not filled to full without topping off. Have a little over 1,000 miles on it and when I filled up the other day I had to further click the pump nozzle like 30 times to even get to 531 mile range. Which means it was stopping well short of 500 miles worth of gas in terms of gallons. Totally not acceptable for a 40K+ vehicle purchase. The hybrid trim models have a major defect and Toyota is pretending like it doesn't exist and trying to keep it quiet.

How does the buyback and lemon law works? I'd appreciate some tips on where one should start!

First you need to take it into dealer 2-3 times (depending on your state’s Lemon Law. File a complaint with Toyota and open a case. Once opened, you will need to be firm and demand that they buy it back. You will not want them to replace with another hybrid because you will be in the same boat you are in now. They escalated my case to their Portland Or office and my buyback was completed within 3 weeks.

We've had our 2019, Made in Japan, Rav4 XLE Hybrid about two weeks [Oct 18, 2019] and fuel gauge needle has gone slightly passed "F" on two fill ups. On both fill ups, gauge needle prior to Fill Up, was between quarter and half tank. Fill ups were 6.6 gal and 7.2 gal to fill tank. We use the "remaining miles as an indicator" rather than gauge needle [accuracy; shown total miles driven 540/39.5MPG = 13.6 gal used. Pretty close

Have had 2 attempts to fix by local dealer based on Toyota engineering input - neither has solved the issue. Have talked with Toyota case manager 5-6 times; she says there is no fix but Toyota is continuing to work on it. For those who did lemon law buybacks, did you have to go through NationalCenterforDisputeSettlement (NCDS) arbitration first or did you go directly through state lemon law?

Never had the Gas Fill-up problem posted by [MichaelS219} or other owners of the 2019 Rav4 XLE Hybrid . Our car is two weeks old since purchased and have had no need to go to dealer or contact Toyota in Texas. Ours was assembled during Sept 2019 in Japan, perhaps plant, parts or assembly methods could contribute to the problem. Then again, we are comparing visual digital data to an analog gauge. Photo is current condition since last posting on this page. Math from pictured data has 7.4 gal remaining in tank or a tad over half a tank, gauge appears to show a little more.

You basically have to get firm with them and let them know that they either need to buy back or you will pursue with the assistance of a third party. When I did that I had resolution within two weeks

For the person who wrote in that they have had theirs for two weeks and it is totally fine. Mine was fine for first 1.5 months then problem began and never ended

The other option is to get your local news team involved if they have an investigative reporter. Toyota has a responsibility to stand behind their products as advertised. If the sticker information says 14.5 gals and 550+ miles and the product does not perform to these standards, well I think you know what that answer might be as with any manufacturer. I have the same issue that has been mentioned here. Someone Senior in Toyota needs to address the issue to the masses who purchased a 2019 Hybrid version. Issues like this cannot be swept under the rug by turning a blind eye to the consumer.

Sticker only shows MPG estimate NOT RANGE OR TANK SIZE. Our new 2019 Rav4 XLE Hybrid has met the STICKERS 40 combined /41 city /38 highway with an actual first 989 mile combined average of 40.7 mpg.

2019 Toyota RAV4 Hybrid Fuel Economy and Driving Range The standard 2019 Toyota RAV4 is now out and available for purchase. However, we’re still waiting on the 2019 Toyota RAV4 Hybrid. However, while we mind the wait, we do have the specification information of the 2019 Toyota RAV4 Hybrid in hand. So, let’s take a look at the best-selling aspect of the 2019 Toyota RAV4 Hybrid which is its fuel economy as a hybrid model. 2019 Toyota RAV4 Hybrid Fuel Economy Fuel economy (mpg) for gas and hybrid vehicles is separated into 3 areas. Those would be city fuel economy, highway fuel economy, and a combined fuel economy of a city and highway average. The 2019 Toyota RAV4 Hybrid has a city fuel economy of 41 mpg. The 2019 Toyota RAV4 Hybrid has a highway fuel economy of 37 mpg. The 2019 Toyota RAV4 Hybrid has a combined fuel economy of 39 mpg. 2019 Toyota RAV4 Hybrid Fuel Tank Capacity Now that we know the fuel economy (miles per gallon) we’ll want to know how many gallons of gas the 2019 Toyota RAV4 Hybrid can store. The 2019 Toyota RAV4 Hybrid has a fuel tank capacity of 14.5 gallons. 2019 Toyota RAV4 Driving Range Using the data of a vehicle’s fuel economy and its fuel tank capacity, we can determine a vehicle’s driving range. The top driving range using city fuel economy is 594.5 miles. The top driving range using highway fuel economy is 536.5 miles. That creates a driving range of between 536.5 miles and 594.5 miles with a full tank of gas.

Hi, new here. I have the exact same problem with our new RAV4 Hybrid Limited that we bought a month ago and now have 3k miles on it. Never been able to add more than 9 gallons at a fill up and only get about 400 miles range. I just called Toyota (800-331-4331) and they claimed to have never heard of this problem and I now have a scheduled appointment with my dealership (Fowler Toyota), who also claimed to have never heard of this problem. Just wanted to add to the discussion more numbers.

Hi, this is a "progress" report. Initially both my dealership and Toyota told me they never heard of the 2019 Rav4 hybrid fuel tank issue. After persisting, now they tell me this is a known problem. My case manager at Toyota says they will inform me as soon as they have a fix (no idea when). In response to my inquiry about buyback they said I will need to follow my State's laws (California) and Toyota's guidelines, but the first step is to take the car to the service department at the dealership and have them test and confirm the problem...

Let's place the blame on the AQMD and environmentalist. To get 10 gal in tank of our 2019 Rav4 XLE Hybrid, fuel has to be forced passed the tank equipped to meet AntiSpill vapor Federal/State requirements, which can be done with patience. Fueling normally will stop at around 8.2gal, but will take more [very slowly]. To me and wife, it is no problem, understanding that the "full tank" STATIC range of over 560 miles based upon shown average mpg at fill up will NEVER be reached and WILL CHANGE the moment gas/hybrid driver applied habits turn the wheels. At present, with an indicated 41.3 average [has not been reset since purchase], range is 217 and miles driven 295.5 gauge showing little less than 1/2 tank remaining.

Yea, screw those environmentalists that won't let me spill gasoline while I fill up my hybrid vehicle. If I want to waste gasoline filling up my vehicle I bought because of its excellent gas mileage then I should have the god given American right to do so!

I just had my appointment at the dealership for them to look at the fuel tank issue. I was informed that the dealership had just heard this week from Toyota that this was a problem and that I was this dealerships first RAV4 Hybrid to inspect. My vehicles fuel gauge exactly matched the description that Toyota had given them on the issue and that as soon as Toyota has a solution I will be the first person they contact (probably dealership hype). I asked for a timeline and they said that now that Toyota is working on the issue it should be quick.

I also got the same issue today, 2 weeks ago I will fill the tank and it would say I had 570 to 580 miles on a 45mpg and after I went to the service Center and an update over the air (no sure what it was for) but now when I fill the tank it will only show me 540miles (the mpg are still the same so it's not that i have changed my driving style)... I'm confused as to what this is all about, was there a glitch that show the wrong mileage or was it due to the piece the service Center change.... I will go back to the service Center and hopefully remember to come here and update on what they tell me. Have a Good one Guys/Girls.

The issue of range is math determined by the most recent gas/mileage usage contributing to the overall average, so range will vary greatly or perhaps not at all based upon the driver and driving conditions. What is most important, are you satisfied with the MPG the Rav4 achieves at each fill up, not the "best computer guess" as to possible range. I'm more concerned as to why Toyota will extent the Ray4's Hybrid battery warranty to 10yr/150,000 miles for the 2020 model and not extent the 2019 Rav4's 8yr/100,000 warranty, Are not they basically the same vehicle?

Having the same fuel tank, gauge issues with my 2019 xse picked up in late September. Haven't been to the dealer yet. Also only getting 35 mpg now - not sure what that is about.

I called Toyota today and they opened a case for me. They said I need to take it to a dealer to report the issue and then call them back and had several options including direct lemon law with Toyota. She said they were well aware of the issue. Here is my video. https://youtu.be/bQ02FYTCvOs This is on a 2020 Rav4 Hybrid XLE only allowed 9.98 Gallons with 23 miles left on the gauge with gas light on. Can someone share the links they used for the 500+ miles advertisement?

I updated the video with the number to call. https://youtu.be/mzAb1u132_0 I did call my dealer and they have been in contact with Toyota and thought a fix may be available in a few weeks. Toyota customer service this morning still had not heard of a fix yet.

Our 2019 Rav4Hbybrid now has over 2800 miles averaging 41mpg and we have experienced early nozzle shut off as posted, BUT RANGE IS NOT A DEAL BREAKER, the new Rav4 is far more technically advanced than was the 2007 Highlander Hybrid it replaced that averaged 24mpg over 218,000 miles. The Rav4Hybrid IS NOT AN FULL ELECTRIC Vehicle were range is of major concern with far and few between stations for recharging. At 1/4 tank or less, I fill tank at lowest nozzle fill setting and once automatic shut off, continue manually slow fill till reaching greatest gallons permitted normally over 10.5 gal ,with removing and reinserting nozzle at times necessary to relief tank back pressure. Guage shows above "F", Range shows 500 or more mile range based upon most recent average usage recorded by program algoritum not necessarily the overall average MPG shown on screen. I believe the issue is the direct result of Toyota'a effort to meet government AQMD and Environmental Fuel Impact rules regarding fumes and spills. To me it is a small issue when considering the overall car performance.

Started the process with my dealer here in Bend OR. The service desk folks (two of them) said they had not heard of the issue and while I waited did some searching on their computer for info about it - they couldn't find anything. So I'm taking it in this coming Tuesday so they can to look into it more thoroughly. After getting busted some years back for hiding issues from its customers you would think they would have learned their lesson and already put out a "problem" notice to all their dealers. Crazy.

So.... Bend Toyota says they found out that Toyota is aware of the early shut off when filling the tank. But that is different than the problem of maybe there not being 14.5 gallons in the tank, or the gage saying you are almost empty (down to 1-2 gals???) when you maybe have still have 3 or 4 gals in the tank. Nobody seems to have a response to that question. And it doesn't seem like Toyota is working on that issue. This is all pretty bizarre - a strange problem to have for this expensive a vehicle and in this day of high tech.

So there is supposed to be a service advisory the dealers have t-tt-0581019 advising dealers/techs of problems. If anyone gets a hold of a copy post it. It would be great to know that it says and how it applies.

The deal breaker for me was that it gets 41mpg in the city. In four weeks, I'm averaging 41.8. I run the gauge down to almost completely empty and get 10.9 in the tank every time. If the spec was an 11 gallon tank, I would've still bought it, so even though I would LIKE for it to fill up to 14.5, since every car I've ever owned filled up all the way, I will not return it if it only takes 11. Maybe they can give me a coupon for the next-gen Rav 4 coming in two years that will get 90 mpg!

Some one will have to explain why mileage range accuracy is such a problem? I suppose if you drive a continuous 500 miles or more, run out of gas and have no gas station in sight to refuel it definitely is a problem! More important is Actual MPG that affects $$ being spend. Maintaining a spec matching the average of 41 or 42 mpg is pretty good these days and more so in California with Nations highest gas pricing.

Called Toyota Customer Care again today to follow up on my case file regarding the fueling problem with my 2019 Rav4 Hybrid Limited. I was told that Toyota is aware of the problem and they are compiling information into a database on this issue but have not discovered what the problem is at this time. In addition to the fuel problem is anyone who lives in a cold climate experiencing the LSD indicator light coming on when cold start and the back up sound not working until warmed up? I had this added to my case file. I recently went on a trip with the vehicle and every time I filled the vehicle to full and the range mileage read a constant 444. Anyone who owns this vehicle and has a case file open should call monthly to have their file updated through Toyota Customer Care, additionally everytime you take it into the dearlership to have it serviced, have the fuel problem documented on the maintenance ticket along with any other issues with the vehicle. Depending on your state and the number of trips required for the same problem without resolution, invoke your states Lemon Law. On another note, anyone with a Tacoma, there is a frame rusting issue, Toyota is replacing frames on vehicles as well as inspecting frames for rust. if no holes are found in the frame from rust, they are in the process of treating the frame with an anti-rust spray on the inside of the frame. If a hole is found in the frame from rust, it will be replaced. Dealerships are replacing the frames and Toyota is paying the bill, the average is about $15K, frame replacement and a loaner car on the dealership to drive while your frame is being replaced.

This is a known issue for both the 2019 and 2020 models. I run my down to an estimated 50km left and I can top up to exactly 40 liters before I see the fuel. Which means 10.5 gallons + 1 gallon in the tank. So 3 gallons of capacity unaccounted for. A hidden 3 gallons reserve would be excessive. So that is probably not what is happening.

On the RAV4 World Forum site, some owners managed to show they can drive about 140 miles past DTE=0 until the vehicle was completely out of gas, which shows that the 'reserve' is more than 3 gallons of gas. They did this to prove the gas tank does indeed have 14.5 gallons usable capacity.

I will have to try that test myself. Considering a single can of gas should be enough to get me to a gas station from just about anywhere it is not that difficult of a test. Then I could learn what the true zero is for my RAV4. The problem with an inaccurate gage is I have had times when I had to take a 20 km detour out of my way because I didn't know if I had to my preferred gas station along my route. If I have an extra 140 km, that means that should never happen, provided I do not make a habit of using the extra reserve.

My dealer checked the fuel system electronics - said everything was working correctly. If that is true, then the tank isn't taking 14.5 gals. Or their testing isn't accurate .

I have a RAV4 Hybrid 2019 with the same problem. Good news, you can drive 550 miles with a tank full of gas. I explain. This fuel system has two problems: 1. The tank is filling up only partially 2. The setting of the the low gas light is completely off Mine comes on at about 28 miles to empty. Today I took an extra gas tank with me with two gal of gas and started driving. To my surprise I could drive 143 extra miles since the low gas light came on and the car was still going (I ran out of time, not gas) That means, when I exhaust the 28 miles to empty and the “refuel” sign shows up on the dash I can still drive at least an other 115 miles With a tank average of 39.8mpg. After that I could fill 13.8 gal, close enough to proof the point. There is a real problem with the tank gauge setting or calibration. If I add the 115 miles to the Estimated 460 miles to empty reading after filling up I am right there where Toyota tells me I should be, around 560+ miles/tank. My tank average was 39.8mpg with mixed driving and 37F outside temp. To fill the tank until the gas gauge shows full I need to click the pump at least 4 times, pull out the dispenser tube and shake the car a bit. It looks to me that this car‘s gauge does not consider the gas in the tank below the reading of the “Refuel” light level. This is where the missing 100plus miles went. I know now my car can do the approx 560 miles per tank, but the last 120 or so are blind driving, unless you manage to set a trip odometer and don’t forget to watch it. Will try to get it fixed during next oil change. I hope this helps to shed new light on it.

The 2019 Hybrids have a different tank than the non hybrid. I have the same issue, dealer knows, it’s been reported, toyota knows, everyone knows there’s a issue. But always the same answer, they’re looking into it and we’ll (dealer or whomever from toyota) will call us. Yea right, nobody has called. Had the car since July. Lawsuit waiting to happen.

I bought my 2019 Hybrid RAV4 in November and am having the same issue - when it is down to 1/4 of a tank, I can only put in 6-7 gallons and that doesn’t fill it up. I’ve been topping it off and can get in 8 gallons. It then reads full but even though the range is listed for ~530 miles, the ranges drops 2-3 miles for every mile I drive. I’ve talked to the service dept. where I bought the car and they are aware of the problem but the sales people are not. I’ve also opened a case with Toyota. They said to get documentation of efforts to fix it (even though service and Toyota both say that there is not yet a remedy). Toyota also told me that I could apply to invoke the Lemon Law or the Buy Back Plan. I’m going to do both. I have 1300 miles on the car and my dealer told me that they would give me 24.5k for the car when I payed 32k 6 weeks ago! Not the kind of “new” car that I wanted!!!

very simply, the epa and marketed mileage is 41/39 for an average of 40 mpg. the reality is that the mileage in the 33 mpg range. I also purchased the vehicle for the mpg and range. I regret it.

At Toyota today. Full tank 10.6 gallons. Bled it till the needle was just above E. Apparently a problem with the gas tank constricting and an air bubble. Toyota is aware and working on a fix. Apparently they replaced a bunch of gas tanks this past summer but had no real Success. Toyota told our dealership to stop replacing tanks and await a fix alert. Obviously they known a problem exists but yet no fix decided on yet.

News report out https://www.fox4news.com/news/consumer-alert- gas-tank-design-flaw

Corrected hyperlink for the news video. Thanks Steve!! https://www.facebook.com/SaveMeSteve/videos/1879239 08979048/

Follow up: I tried to invoke the Lemon Law on my car. I was turned down as the issue isn’t a safety or malfunction issue. They also offered to replace my tank which I declined since I’ve read that the replacements haven’t helped. I like the car otherwise so I’m going to hope that a remedy comes out soon.

My original post for this story got flagged and taken down from Facebook. Hmm..... If I reposted it and would encourage you to head to www.facebook.com/savemesteve ...and share it (Even if you did so already). i can’t say why it was taken down but somebody had to have reported the content for that to happen if you don’t have Facebook and would like to view, here is the link. hhttps://www.fox4news.com/news/consumer-alert- gas-tank-design-flaw

Your total miles to empty is based on your mpg average, not how many gallons of fuel your putting in.

Yup, same problem with ours. Can only get about 10.5 gallons in, max range 391, gas gauge reads about 7/8 full.

Our 2019 hybrid was repurchased by Toyota last week. Started the process in June, 2019. Took car to local dealer who worked with Customer Care to try several fixes, including changing the gas tank. Nothing worked so in November I requested Customer Care rep to repurchase through TX lemon law. Was contacted by a district Customer Experience Mgr who handled case to repurchase. If you don't want the car as is, my advice is to be firm, invoke the lemon law and work with the Toyota rep.

Today my dealer replaced the gas tank. It is a Japanese-built 2019 Rav4 Hybrid that I was never able to properly fill the gas tank on. I complained both to the dealer and Toyota USA. I wasn't expecting to get a call asking me to bring it in so they can replace the gas tank - to fix the venting problem preventing normal fill-up because of a slight difference in the shape of the gas tank in some production runs of the Rav4. The dealer filled up the tank for me to test it (and it is indeed full but I wasn't there to see how far past the first auto shut off the dealer took it). Anyway, I haven't tested out filling it myself yet, but I thought I'd let y'all know. BTW, when a friend called her (different) Toyota dealer on my recommendation about fixing her gas fill problem, her dealer said they hadn't ever heard of this problem. That must be the recommended lie, but there was a lawsuit and EPA emissions violations and if one notices the problem and complains, Toyota will replace the gas tank. Presumably based on a technical bulletin to service departments. https://www.carcomplaints.com/news/2020/2019-2020-toyota-rav4-hybrid-fuel-tank-issue-lawsuit.shtml

The issue is the design of the gas tank. I have had the same issue. Today when I filled up, the flow rate of the gas out of the pump was much slower than normal. I was able to add 2 gallons more than I normally do. The problem is the design of the fuel tank in the hybrid causes the auto shut off of the gas pump to turn off before the tank is full.

I just received a JD Power survey about how I like the new Rav4....They got an earful with links to many of the URLs that were given on this site. What I still don't understand is how Toyota can help one customer and not another for the same issues. That is what I think is not right here, along with the sales people playing dumb still not knowing of the issue. Does anyone know if we have to contact the group doing the class action law suit to be included?

Only been two cases reported at my dealer. Simple solution is to enjoy the Rav4 Hybrid mpg and performance, file a fuel tank case with Toyota to obtain a case # [ 800 331 4331], record condition with dealer, wait for the necessary world-wide recall and join a class action law suit such as that listed below or whomever.... Ron [Ours is going in for 5000mile scheduled maintenance] CARLSON LYNCH 1133 Penn Avenue, 5th Floor Pittsburgh, PA 15222 Phone: 412.322.9243 Fax: 412.231.0246 www.carlsonlynch.com

Yes, I have it. Purchased my Rav4 hybrid in May 2019. Noticed it maybe 4-6 weeks after purchase. Mine only fills up to 3/4...sometimes a little above & have had it a little below. If I trickle it it, I can get closer to 530 miles per the DTE; however, I don't want it to overflow so I have stopped doing this. Agree, no fix, only the suggestion per Toyota to possibly replace the tank to mitigate the problem; however, it will probably not fix it. Seems like time and money spent for nothing that Toyota could put into loaner cars for people that are effected while they are replacing the tank if and when a fix comes. I just don't like needless things done to a vehicle and like it "factory fresh" if possible until an actual fix is available. I monitor several forums and the people that have had the interim fix, say it has none nothing to help the issue. I did report this to my service department representative on my 5K service; however, I noticed when I looked at my paperwork a couple of days later, it wasn't included. To be fair, they may have put it in the computer but I am not sure. I have since that time obtained a case number from Toyota and the representative I spoke with was well aware of the issue. When I go back at 10K service, I'll ask Toyota to put it on the paperwork. Other than this I am pleased with the ride, handling, etc.