RAV4 2019 hybrid won’t fill up

This is happening to my car. The dealership doesn't know why and it was sold brand new with this issue. I did call Toyota today and a case manager is supposed to call back in one day. The dealership told me they fixed the issue by resetting the computer but the next time I went to fill the car up, the same problem so either they lied or the computer needs to consistently be reset? Not something a consumer can do anyway. Furious that this brand new car has this issue.

The dealership reset my computer to which did absolutely nothing, everyone needs to file cases with Toyota the more documentation the better! Mine only fills just past 3/4 therefore we are all getting robbed, because we’re not getting the range that was advertised to us when we made decision to purchase these hybrid Rav4’s Toyota says they are aware and they’re working on a fix, however in the meantime we have overpaid for a product that was fraudulently advertised.

Toyota said that they are working of a fix actively and are aware but until they have a set fix and a recall, there’s nothing they can do. I have a case open with them so anyone with this issue should call them directly because individual dealerships don’t have a way to fix this right now. The more people that file a complaint the better. I’m able to fill the car past the stopping but I need to keep the car on to see the gas gauge and make sure I’m not going much past full.

See the major and ongoing posts about this 2019 RAV4 Hybrid model fueling issue on the RAV4World Forum website, it's the #1 topic by far on that website, which should tell Toyota something about the seriousness of this problem.

Having the same question here. But i was thinking that Toyota was very conservative in estimated km left and was keeping 10-12 litres of gas when the computer say that we have about less than 10 km left. To be sure of that i'm planning to run it until i'm really out of gas (doing it with a small jerry can inside) 8-). I want to know how much km i can do when the computer say i'm near zero. That my theory.

Hey let me know what you get when your done that be very helpful.

This is happening to my rav4. I just got off the phone with Toyota Headquarters. They said they had no other complaints about this problem!! WTF!!They gave me a case number but said there was really nothing they could do. Calling the dealership was also no help. The service tech.said it was the gas pump I was using. We all need to keep calling until this gets resolved. We all over paid for this car. Maybe we should contact aT.V. news investigator. Then Toyota can't say they have never heard about it.

They are lying then. My case manager is Pam and her number is 1-800-331-4331, select option 3 and enter extension 73812. This is a widespread issue. Mine technically qualifies for the Lemon Law because it has been into service 3 times for same issue and they currently have no fix. You need to push harder, because legally (depending on your state's laws) they will have to replace or refund you. Or a class action suit needs to be started to get their attention.

Go in and insist service advisor puts your problem in writing! Forget calling. My XSE had the warranty repair yesterday at Elk Grove CA dealership. I’ve attached screen shot of my invoice. First time ever, dash display reads slightly over full and the DTE showed 550! I won’t truly believe it until after the next couple of fill ups, but I’m very encouraged. Plus have full tank of gas on Toyota. Hope this helps.

So, is the tank getting filled and the gauge is wrong, or is the gauge wrong by not showing the correct amount of gas in the tank?

When I first took my XSE in for 5K service, Toyota corporate made dealership tech do a software “fix”. Then the tech said he tried to fill, from nearly empty, and forcing it after 8.9 gals when it automatically shut off he got it painfully to 11.2 gallons. He told corporate the display now registered Full (software fix) BUT my problem existed. From 8.9 to 11.2 (when gauge showed full) took many click click clicks to force the fill. The software only created the illusion of a full 14.5 gallon tank. I’m sure they are doing post mortems on enough of these original tanks to identify the problem. Our service tech theorized the bladder inside the hybrid tanks created too much back pressure to allow a fill.

It has to be the tank not the gauge since once it "clicks off" that it's full, you can manually get out of car and fill it to full (and gauge will reflect that) and get the correct range out of the tank. The "miles til empty" will not be correct, but if you use old school calculations at the next fill you can still calculate your mileage.

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.

my is 2019 hybrid xle and only got 457mi per tank, my mpg is 39.8

Does anyone fill up their tank and drive until it's empty to see how many miles they can drive？

When I picked car up after purchase my XLE got 545 miles so it can go higher. Has anyone’s gone higher than that ? When I will it now it stops around 450.

Mine worked fine at first (first two months) then the problem started out of nowhere Everyone needs to put pressure on Toyota because this is widespread and not acceptable for a brand new high quality Toyota.

Hi Everyone, I have had the same issue with my Rav4 Hybrid since May 2019 in California. The tank goes to empty, it only fills about 9/10 gallons before the pump shuts off and I don't get the full mileage range. I have taken it into Toyota Dealer 3 times, and they tell me Toyota is aware of the issue, but there is no fix. We all need to file more complaints and official issues with corporate to get this resolved. They won't budge until there is an overwhelming wave of problems. NATIONAL TOYOTA CUSTOMER SERVICE HOTLINE: 800-331-4331

After tank, sending unit, and gasket replacement plus software “fix”, my XSE continues to have the same issue. I made an return service appointment but service advisor called and cancelled it per Toyota Corporate instructions. I am instructed to wait for repair,,Toyota is working on it. Grrrr.

Bought our 2019 rav4 limited AWD in may. Its had this 9-10 gal refill when near empty since day 1. Coming up on 5000 mile check up and will be opening a case file, and threaten for a replacement if it is not corrected. Maybe contact CBS consumer people and have them walk into Toyota with cameras. Having to fill up every 9 gallons is ridiculous, and not what I paid higher $ to get.

I opened up a lemon law case complaint. If you contact Toyota directly and open a case number, your case manager will file for you if you wish. I just submitted all the requested paperwork. The more people that do this, the faster this problem will be fixed!! Please, everyone, call and complain and file lemon law complaints!!

Today is 07 Oct 2019. I am in the US. I e-mailed Toyota on Friday to report the same problems; the reply asked that I call. I called on Monday morning. "There are no reports of any similar issues in our database," according to the person I spoke with. I mentioned the many reports I have seen on various online message boards. She dismissed them with "well, they're on the Internet, not in our records." Her only recommendation was to have the dealer look at it.

I can give you the name of the person on my case. It is Patti Lohden. Perhaps ask for her.

Hi - I bought a new 2019 RAV4 XSE Hybrid in California in August. The range on the trip computer is usually only around 450 miles. I have been averaging 35-39 MPG per tank. I run the fuel gauge down WAY past empty (30-60 miles) after it says "Refuel" and when I fill it up, I can only get about 12 gallons in the tank. I should have at least 100+ more miles range as there are 2.5 gallons in the tank, even when empty. The fuel gauge and trip computer clearly needs recalibrating. This is driving me crazy! I called Toyota and they said there was a 2 gallon reserve - but that still doesn't account for the range / gauge discrepancy. I am going to call Toyota again and file a complaint. I'll tell the dealer service department about it when I bring it in for the 5K service in a few months. Please advice if anyone comes up with more answers or a solution.

I have provided my Dealer Service Dept with screen shots showing the tank 3/4 empty and showing that it will only allow me to put in 6.4 gals before the pump clicks off. When I start the car the gauge shows the tank down 1/4. Doing the math, I should be able to get 10.5 gals into a 14.5 gal tank (when the tank is 3/4 empty) and the gauge should show full. I've registered the problem with Toyota and received a Case Number which I also provided to the Dealer Service Dept. Both the Service Dept and Toyota Customer Service were very helpful and understand that this is an issue. The Service Dept. called me yesterday (saw them 2 weeks ago about the issue) asking if I could bring the car in. They have a couple of things they want to "try" - and mentioned twice that what they are doing is not a "fix" but that they've been asked to try a couple of things. Maybe they are actually going to see if the tank on the car is a 14.5 and not 12.5 gal tank. As gas gets more and more expensive in California I am happy I purchased my Rav 4 Hybrid even with this fueling issue.

I’ve already posted this a month ago on cargurus , must be on another associated topic, also have Many posts on Rav4world. I bought one of the first 2019 RAV4 hybrids very late April, just shipped from Japan. Experiencing the problem from day one. I really need the mileage range as advertised, a lot of road trips for me. The dealer replaced sending unit in the tank, keeping the Rav for 3 days, had a field engineer look at it too. Rav4 was returned to me not fixed, dealer said they notified Toyota Corporate the same. I searched the web, found RAV4world with 1300+ posting the same issue, I read most of the posts, (thread was closed), found the new RAV4 world thread same topic (continuation). This is where I found out to call Toyota Corporate ,obtaining a case number. Here I am 2 months later, Toyota Corporate has agreed to repurchase the RAV4 hybrid, full price, tax , license, interest paid on the loan. They’re deducting for my mileage new to mileage at time Toyota dealer attempted to fix. 3880 miles, (I now have 6K+miles). Dealer will contact me this week to set up transaction time, dealer will have the check from Toyota Corporate. I’m mixed on this, the fuel filling issue aside, I really love the RAV4 hybrid, my 7th Toyota hybrid, obtaining 39 to 44 mpg on this RAV4. Hopefully Toyota will do the right thing, step forward and fix this issue for other RAV4 hybrid owners who wish to keep theirs. I might then revisit the RAV4 hybrid again, (maybe even moving a notch above my LE )

Ok guys, i've done what i've was planning in my first message. I drove my rav4 until i went out of fuel. I've a few interesting numbers from this experiment. 8-). I've got the low fuel message when my odometer was around 5950 km. This message appears when less than 50km left. So if the information is accurate, i should ran out of fuel around 6000km. But since Toyota is very conservative in its estimate, it's far from true. My car ran out of fuel when it reached 6224 km. So i was able to drive 275 km after the low fuel message. Quite a lot more than expected. The fuel tank capacity is 55 liters. I've put around 10 liters of fuel when it happened with a jerry can and i've add 45 more liters a few minutes after at the gas station. So the capacity of the tank is really around 55 litres. So i came to the conclusion that at least 15 liters still left in the tank when the low fuel message appears on the screen. I don't really recommand to try this since now, i'm having a check engine that need to be reset somehow. I will try to disconnect the battery to reset it. If it don't do it, i will ask my dealer to do it when i will go for the 8000 km check up in a few weeks. My car running fine now but with this annoying message on the main display. So for those who understand only miles, in resume, you can drive around 150 more miles after the low fuel message. Dont stress. 8-) Sorry for my bad english.

Claudeb, I think you have answered many questions with your bold experiment, hopefully your RAV4 hybrid survived. Your answering, the fuel tank actually takes 14.5 gallons, the reserve is not 2.2 gallons, more likely 3 to 4 gallons (when the reserve light comes on) you drove 150 miles on reserve. This sounds more like a problem with the fuel gauge, sending unit or a computer which governs both. Maybe if the engineers at Toyota read some of the great posts on these forums, possibly they could actually fix our RAV4 hybrids

Took my car to the dealer. Same story: no such problems reported. The want me to bring the car back close to empty so they can remove the tank and perform some tests. Too extreme for me. Will live with it.

Yeah, I find this is hit and miss. When I'm arrive at the pump, I look at the gage and try to figure how much it will take. Sometimes it takes 3-7 shut-offs and restarts to fill it up. Sometimes not. If/when they get to bottom of this and issue a recall, THEN I'll take my RAV4 in.

When i ran out of fuel, i've got the Hybrid system fault and a yellow check engine. The day after, i've open the hood and check the oil. Closed it then yellow check engine was gone. Back to normal. Quite happy. Going to the garage today to install an hitch for a small trailer.

Just got back from the dealer in Idaho and completed my buy back. Purchased a gas model 2019 Rav4 which has COMPLETELY different fuel system than my XSE Hybrid, and the tank was beyond FULL when I received it :)

Good for you! I completed my buyback transaction at my dealer Thursday 10/17. I have a Camry hybrid that I will be using in the meantime, however I really love the RAV4 hybrid and will wait awhile, hopefully Toyota will correct this issue soon. For those who love their RAV4 hybrids will get theirs fixed and I will possibly purchase a new RAV4 hybrid, step up to a XLE or Limited from my previous LE.

Is it possible that by mistake or intentionally Toyota installed a worng fuel tank in some of their 2019 RAV4 hybrid vehicles? I just checked the fuel capacity of 2019 Toyota Yaris. It is 11.6 gal, which could explain why we can only pump a Max of 11 gallons when our RAV4's tank is near empty.

Hi GuruNVHQ8 - it's a nice theory, but I can prove it is incorrect. First of all, this is happening to 100% (ALL) 2019 Toyota Rav4 Hybrids - not just some of them. And it is NOT happening on 2019 Toyota Rav4 regulars (non-hybrids). The other thing is I, as well as many others on this thread, have tested the fuel tank size by overfilling at the gas pump. Personally, I ran my car (2019 Toyota Rav4 Hybrid) 75 miles past the time the "fuel is empty" light came on, and then went to fill at a gas station. I filled it up to 13.5 gallons. So the tank is clearly 14.5 gallons, and the light that the fuel tank is empty clearly comes on with a 2 gallon reserve. The problem, that Toyota has known about since Jan 2019, is that when filling at a gas station, the fill will only go to about 9 gallons, and you have to force the last 4-5 gallons in by manually clicking to put more gas in - which is a safety issue, a false advertising issue, and a major pain for all Rav4 Hybrid owners. More fun from Toyota Corporate, after creating a case and getting a case manager, I heard that the ultimate fix for this will not be via a recall (where owners are notified they can take their car in), but via a "FTO fix", which means the dealerships will be informed there is a fix, but not the owners. So it will be up to owners of the cars to constantly call their dealerships every week for the next 4 years, in order to see if Toyota issued that "FTO fix" or not. When it's issued, we can take our cars in to get them fixed. But we won't be notified. And I have no faith in the dealerships notifying us because the dealership I bought my 2019 Toyota Rav4 Hybrid from (Toyota of Lake City Way in Seattle, WA), LIED to me about a whole bunch of things, and I'm in arbitration with them about those other things. This whole situation is a SNAFU of major proportions, and I hope Toyota gets sued for this. I would gladly be a party in a class action lawsuit.

GuruN9FFX thank you for your response. I didn’t realize it was in 100% of the 2019 rav 4 hybrids. I am participating in the buyback but I was going to try to get another one that didn’t have the issue. They are probably doing the buyback in hopes of not getting sued because they sold the cars knowingly to people like this. I’m just debating what to do now because even with this very annoying issue it’s still more fuel efficient than their gas version. On the flip side, the fact that I paid top dollar for a brand new Toyota with a defect is unacceptable. I wonder if the 2020 model has this issue or the 2018 model for that matter (even though 2018 is significantly less sporty looking). Then Honda is coming out with a hybrid CR-V in January. Do I want and get that? That’s the first of its kind it may have issues and kinks to be worked out. Then again, Toyota has been making rav 4 hybrids for several years and this year there’s an issue. Ugh I really don’t know what to do! Perhaps lease something for awhile? Anyone else know what they are doing about their buyback?

I too bought a 2019 Toyota Rav 4 Hybrid XLE which also fills to only 3/4. Started a case file. Toyota had me bring the vehicle in to change the gas tank. Received the car back with a full tank. When I tried to refill the NEW gas tank, I still have the same issue. Please, everyone needs to complain to Toyota to have this problem rectified. This is TOTALLY UNACCEPTABLE!!

Same issue with my 2019 Toyota RAV4 hybrid. I consistently need to feed the last 2 gallons by pressing the gas pump lever just slightly to prevent the auto stop clicking.

The 2019 Rav4 XSE does have a 2 gallon reserve in it. you will only be able to put the entire 14.5 gallons in the vehicle if you run it down to the E and keep driving it to exhaust all the fuel and reserve. after the fact you should fill up and see how much you can fill it to.

Having the same issue here. Of course when I researched the vehicle none of this came up ha ha. 2019 Rav4 LE Hybrid. Gets 3/4 full and that's it. I'll try my dealer but won't be holding my breath. If I hear of anything I"ll let you know.

Go to Rav4world.com under RAV4 hybrid fuel filling problem, you’ll see 1400 posts with RAV4 hybrid owners having the same issue.

I posted yesterday about my same Rav4 issue. I emailed the service manager at the Toyota dealership where I bought the car. His response was this: "Yes, it is a known issue on the RAV4 Hybrids. Early information indicates a problem with the fuel tank itself. Toyota is aware and working on it, but I have no ETA for a fix yet. While inconvenient, I would recommend not filling the tank beyond when the pump shuts off automatically as there are vapor hoses that should not get liquid fuel in them. It can create problems with other components in the emission control system. Hopefully, Toyota issues a remedy for the condition sooner rather than later." If I hear more I'll post.

I had my gasoline tank replaced for free by dealer; authorized by Toyota. I can now fill up completely instead of 8/10 of the way. I had to slowly get the last 1.5 to 2 gallons in by holding the gas despensor down lightly.........I was achieving 43.5 mpg for 10k miles before the gas tank replacement.... 3 fill ups since gas tank rep leave the I am averaging 36.5 mpg... I will report this to local dealer

My new 2019 RAV4 hybrid XSE has the same issue. They finally replaced the tank and the problem went away.

My wife and I both have a 2109 RAV4 Hybrid with this gas tank problem. We both now have Toyota corporate case numbers. They are working on a fix and suggested notifying the dealership with the case numbers. I am able to fill up completely by pulling nozzle out at back pressure click-off and re-inserting (about 12-18 times). Takes an extra 3-4 minutes to fill-up. We each have a three year lease; so they will get these back!

I purchased my Rav4 back in June, and having the same issues as above, my dealership replaced the fuel tank. This was a waste of time, as the tank which once would fill to capacity after being replaced, has reverted back to stopping short of full. I was told by dealership that they are waiting on a fix from Toyota and cannot do anything further. Not what I expected from Toyota.

Purchased in April 2019 and received in August 2019 the ordered Limited Hybrid model of choice. Having the same issues with fuel tank as all have stated. Where do I go to file for a case number? Toyota will make it right!! Hopefully, :-

Hi everone- I bought my rav4 hyrbid in may and am having the same issue. I filed the complaint, but got my rejection letter today stating they reviewed all warranty history and repair orders, and at this time they don't believe the vehicle suffers from a defect in materials that impairs the vehicles use, value or safety.. Has anyone been rejected yet? What do we do now?

Hello, new here. Purchased a 2019 RAV4 Hybrid LE from Toyota dealer in Mesa, AZ. On our road trip home to Albuquerque, NM (434 miles) we were very excited to get home and still have fuel and range!! NOT EVEN CLOSE. Had to put gas twice before even making it home, what a let down. Like most who buy these Hybrids, we spent the extra money over the gas model to do just the opposite. Glad to know we are not alone but this is still extremely unacceptable, especially from a reputable company like Toyota. How can they not have a solution or recall given the amount of time and number of people that have had this problem? What if we ran out of fuel and became stranded on the side of a highway because we trusted our $30k brand new vehicle to at the very least, give an accurate fuel reading? Called the dealer the next day and like most of you had said, they claimed to be unaware of the issue. They even had the head service tech call me and say the same thing. They were apologetic and promised to make it right but I find it hard to believe that Toyota has not updated the people selling their products of this widespread issue. Also spoke with corporate and started a case as recommended by you all. They stated they WERE aware and that Toyota is working on it but without recalls at this time, only a technical bulletin and urged me to take it to the dealer so they can diagnose and rule out anything else. Also very apologetic and kind but now I have the headache of the dealership wrenching on a 4 day old vehicle. Not mention, based on what we have read it sounds like multiple trips will have to be made to the service dept. What a nightmare, just in time for the busy holidays. We expect an answer/solution soon or will pursue a lemon law buyback. I will also be posting a YouTube video warning potential buyers of this issue. I feel stupid for not finding this out before making the purchase, but here we are. It is up to us consumers to shed as much light on this as possible!

Hello all, I have been trying to keep up with this thread in hopes of someone finding an answer, but it is obvious that we are still a little ways away from an answer from Toyota. I have a slightly different issue that I was hoping someone else could confirm (or not). My 2019 RAV4 Hybrid XSE is about a month old now with about 1,350 miles on it. My first tank of gas was on the dealership so I had no idea if it had the fill up issue. However, it is way full and did not move the needle off of full for quite a while. The gas mileage I was getting was unbelievably terrible for a hybrid. I have owned many cars and have notoriously gotten better than the best stated gas mileage (including a prius c at 64 mpg), so I as expecting to be able to at very least get the combined 40-41 mpg. I however, am struggling to get above 36 mpg with mixed driving. I do not have a lead foot and actually drive very economical (I once got 32 mpg out of a jeep patriot), so I am just very confused. I only made it 370 miles before I filled this tank up too. Well, the first fill up was a little less than half a quarter tank left and only filled 9.5-ish gallons...but the tank read full so I was going to test it out and believe it. It must not have been correct because almost as soon as I left the gas station it dropped off of the full mark. However, this tank of gas was able to get me up to about 39 mpg with very economical driving and that was still a struggle. I was able to squeeze 392 miles out of that tank even with the better gas mileage. I went to the gas station and filled it up and as I was pulling in the "need gas" light came on, so it was kind of a perfect test. I was able to put 10.5-ish gallons in this time and the indicator showed full at that point (first click to stop the pump). From what I am reading it is supposed to be a 14.5 gallon tank and when the light comes on it should have 2.2 gallons remaining. So the math is not quite adding up. 14.5 - 2.2 = 12.3 and 12.3 - 10.5 = 1.8. So I am "missing" almost two gallons and I am not sure what is going on. Plus, after the recent fill up it did the same time with moving off of full almost right after I left the gas station and currently I am again struggling to get above 36 mpg. Has anyone else had this issue? I normally would say it was just the driving style, but since I have notoriously been able to beat the stated mpg on all the vehicles I have owned, it does not make sense that this one would be getting much worse gas mileage while being a hybrid.

I have a few tricks that work. 1. When you fill up, turn the nozzle upside down and fill at a slower rate. 2. Burp your vehicle. You may look ridiculous doing it. Open your Hatch, sit on the tailgate and bounce the RAV4 up and down. It is a saddle bag gas tank, which has 2 sides to it, and helps move the gas from the fuller side.

Has anyone pursued lemon law on this?

@stacy I have exactly the same problem that you are experiencing with only one difference that my car is only doing 33 mpg. I submitted a claim to toyota and they replied with a letter that this is not a lemon case and they won’t be able to assess me with anything for now!!

@milocat2019 I have talked to Toyota and they will help you with the lemon law. you just have to go to the dealership once to have them document the issue and call Toyota customer service back again. I have updated the video of my care and the number to call. I am trying to work with the dealership first, they say a fix may be available in a few weeks, but Toyota customer service is not aware of a fix yet. https://youtu.be/mzAb1u132_0

I have the same issue with my RAV4 hybrid XSE. The most I have been able to fill up is 10 gallons which gets me to almost full. The highest average MPG I have gotten per tank is 35mpg despite using eco mode and driving to optimize mileage. Sounds like there are good batches and bad batches of the hybrids. Some people have no problems at all and get better than 40mpg, while the rest of us with the defective tank get less than average mpg and can't fill up.

Take your car to the dealership to report this. They are needing more people to speak up here as they say they don't have a fix yet. I am taking mine in Monday.

Mine went in today. I am showing 38.8 mpg with a 386 range at full. The dealer is claiming that they don’t know what’s wrong and want me to track mileage. It’s simple math. I asked if they called corporate about a fix and they did not. I’ll be forced to do what they want but I know darn well I can’t pump 12 gallons in that tank.

Are 2019 Rav 4 has the same issue, what i do is when the nozzle stops I pull the nozzle out wait 20 seconds for the fuel to settle, then I can fit in another 3 gallons usually it stops around 8.5 gallons and I can get it to 11.5 gallons by manually topping it off and the car will have a full tank when I use this procces

I will take a video after I get home from the holidays and post my process to help as a temporary fix

Same thing is happening to me only goes up to 9 to 10 gallons (manually).

There is a story that came out yesterday in an autoblog magazine/site. Here's a link https://www.autoblog.com/2019/12/23/2019-toyota-rav4-hybrid-fuel-gas-tank-shape- problem/

I went to the dealer today and they said it is a known issue and they have instructions not to fix it. They said since they have this info they don't think it will count as a trip to fix the issue for a lemon law. Waiting for a Toyota case manager to call me. Just got gas with only 4 miles left on the estimator and was able to put in 10.89 gallons.

jpiggott I just shared the article I posted above with the service manager at my Toyota dealer. He said that article had more info in it than Toyota has shared with them. He said no word on a fix yet...I mean I like the vehicle and will keep it. I don't drive tremendous distances, but it would be nice to get a full tank! Thanks for you info.

Thanks I need to get in touch with the writer of the article to make sure they know it is 2020 hybrids as well.

They seriously should stop selling them They know they have a problem. Why not tell people and give them assurances they will fix it.

I called in my Toyota service manager on the 22nd to get an appointment specifically for this issue. I had no previous history of service calls. .The technocal advisor started by denying it was a problem, i insisted, they said they would look into with Toyota Canada, and on the day that articles wa s out, i got a call from the Service manager telling me that it was an unknown issue to Toyota Canada. So either i got BS from the SM or they are oblivious to that issue. In both case it reflects poorly on Toyota. I was denied a service call. Thats my first Toyota, and with such service for a RAV4 hybrid limited I am already starting to regret my choice.

Once the fuel pump clicks off, I wait 30 seconds and then start again. Repeating this process a couple of dozen times, I can get enough gas in that my range indicator gets above 500 miles. Usually an additional 3 gallons or so from where it started clicking off. Also after it clicks off, helps to not press gas lever down hard. Just kind of let the fuel dribble in.

Actually, premature shut-off of fuel pumps is not totally uncommon with other past vehicles of various brands, as a Google search would quickly show. It's more sensitive for the 2019 RAV4 Hybrid, since the vehicle driving range is supposed to be a strong selling point. Until a fix comes out from Toyota, I've resorted to allowing the fuel pump to shut off automatically after a normal-speed fueling, and then proceed with doing a 'trickle' fueling method by manually holding the fuel pump handle only part-way down, to provide very slow fueling. With the pump nozzle inserted completely into the filler pipe, the pump will still shut off automatically as the fuel level rises (to avoid an overflow). Using this method, I've been able to completely fill my tank to reach DTE of 550+ miles, with fuel gauge reading well past the 'F' mark. And it normally takes only a few extra minutes of fueling.

So today i decided to try and trickle in gas after it clicked off. It worked. I am at the F mark for the first time and the range of mileage was estimated at 526. Typically after it's at 3/4 or so with a range in the low 400 mile area. There still may be some space left in the tank to fill but it did work. Only took a minute or two to do this. My only concern is am I risking damaging the sensors by filling up past the first auto shut off? I'm guessing no as I think it is a matter of letting the gas settle, getting a chance to fill in the tank, and adding more.

@Najorpro or others can you post the year and trim level as answers are provided? Curious if others with 2020 are having the same issue.

Mine is a 2019 Rav4 Hybrid SE.

I was told by the Service Manager at the dealership that I MUST stop filling when the pump clicks off the first time to avoid potential problems with the yet unresolved issue. It is really hard for me to do so as I purchased my 2019 Rav 4 Limited completely loaded complete with running boards. Out the door price including sales tax and license (in CA) over $45,000. This is not, in my opinion a $45,000 car. I opened a report with Toyota back in August when I first experienced the problem and also a separate report directly with the dealership. I do not want to return the car on the Lemon Law but believe we should all be compensated for the problem of inability to fill the tank and the time it is taking to find a fix (if they are even looking for one). Also, I am abiding by the service manager's instructions NOT to keep clicking the pump after the initial shut-off occurs. I don't want them saying I did something wrong thus voiding any repair that would be done (should one ever be found) under warranty.

The 'trickle' method to fill up the gas tank as fully as possible is not the same as topping off by repeatedly clicking the gas pump at normal fueling speed. The trickle method is like filling up the gas tank from a fuel can, where the fueling speed is slow and at low pressure. This method, like fueling from a gas can, should not cause any issues or void the warranty, as the pump sensor will shut off the pump when the tank is actually full (and there is no need to click repeatedly). By comparison, clicking the gas pump repeatedly at normal fueling speed (aka 'topping' off by squeezing the pump fully) can possibly cause overfilling problems.

I bought The XSE Hybrid 3 weeks ago. Same issue here. The tank only holds 10 gallons. I called Toyota and they said that they haven’t heard any issues, this is the first time. Taking the car back to the dealer. I’m going for a buyback.

I purchased my 2019 RAV4 Hybrid in October and Immediately started having the same tank fill problem. When the dash gauge shows “Empty” (which per Toyota should mean it has only 2 Gallons or less remaining) I can normally only get 9 to 10 gallons in the tank. I reported it to dealer and brought it in for service; they could not do anything to fix it. At first they denied they had ever heard of this issue; later admitted they had heard of a “few” cases. I then reported it to Toyota Customer Service and got a Case # assigned. The Case Manager that I spoke with sss as id, after I questioned her, that she had heard of “2 or 3 cases like this in other states”. Over a month now, no response, so I am planning to start contacting the Dealership and Toyota CS asking for an update

Toyota headquarter came back with an option of buyback the car, replacing with a new one or getting a different model. Just mention the “lemon law” (if apply in your state) And they are obligate it to take the car back if they can’t fix the problem. They did ask me if I was willing to wait until they can figure out how to resolve this issue, I told them “no”. Looking forward to get a new car.

@Guru8635H if you are offered the buy back, can you ask if that includes the state sales tax. For Illinois that was around $2000 that I would want back. Jeff

I have the same issue with my 2019 RAV4 Hybrid XSE. It doesn't fill up. I have to keep force filling it. It's real pain since I commute about 500 miles a week.

Toyota said that in regards to tax & license refunds, it depends. They are preparing the buyback offer, this is a legal process and it will take from 30 to 45 days. However, if I want the car to be replace, they won’t charge me anything.

I made an appointment with the dealer tomorrow to look at it. I also called Toyota today and got a case number. They are aware of this issue where the gas tank only fills up 3/4 to 7/8 full and say there is no fix as of today. I like the car and hope there is a fix for it. I don’t like trying to click click click the final 3-4 gallons into the tank. On some other forums I saw a few tricks to try with varying amounts of success: 1. Use the manual lever behind the panel in the storage area on the same side of gas latch to open gas latch. Open the panel with a screwdriver with care! 2. After the initial click off, leave the nozzle in and go inside the car and press the gas latch release again to reset something. 3. After the initial click off, shake the car a little to force fuel down. 4. Use a 6” ramp/block to drive the latch side rear wheel up on. Tilting the tank a little. 5. After the initial click off, wait 30 seconds, try again. Lather rinse repeat until full. 6. Bring along spare gas cans and fill those up with 3-4 gallons. After filling RAV4 and nozzle clicks off, use the gas cans to add the additional 3-4 gallons. What a pain, right?

I just received my FedEx letter today from Toyota to start gathering all the sales documents and any aftermarket expenses I have on the 2020 hybrid Xle. What I am curious about is what options they give you for buy back or moving to a new car. Is this to another trim of rav 4, or like to a new model like highlander. Or money back to go to another Makr(honda...) I'm worried about having to double pay state staxes will ridiculous new Illinois laws on a buyback or trade.

The way the buyback works is they will look over what you paid total including sales tax however they pro rate some of the value based on mileage/wear, so you will not get the full amount back. In my case I just decided to get a 2019 Rav4 xle premium gas model because I lost confidence in the hybrid, so I got the check and turned around and purchased that. You can opt for the exchange but it has to be comparable replacement.

Not much sense in exchanging for the 2020 hybrid if it has the same problems as the 2019. probably have to wait for a 2021 or just give up on the hybrid like the last person did. I cant believe they are still selling them without disclosing the problem.

Exactly which is why I opted for the gas model which actually fills up to full like normal cars should. If you replace with 2020 you will be potentially getting the same damaged goods...and yes it is SO unethical for them to continue to advertise and sell these defective models

I got the car in September 2019. I will always get 9 to 10 gallons and the pump would click off. I filled up yesterday and it only got to 10 gallons but this time the fuel gauge got very close to the full mark yet I was only able to put 10 gallons in the tank and my gas tank was almost on empty. I called Toyota, got a case number, and who I spoke to at Toyota was well aware of the issue. And said that now it's time to work with the dealer and start documenting the efforts to find a remedy to the problem. Unfortunately, from what I have been reading on this thread, it appears that there is no remedy at this time.

There is the problem. The dealer wont do anything. There is a TSB that tells them no action is recommended and that its "under investigation".

Simple method to fill up COMPLETELY: I have posted about this previously, but it's worth repeating... Right now, my fueling method involves 'trickle' fueling after the initial pump shut-off at regular fueling speed. Using this method, I am able to fuel my 2019 RAV4 Hybrid completely each and every time (gauge showing past Full), without any fuel spills, and only taking a few minutes of additional fueling time. The 'trickle' method consists of manually squeezing the pump handle gently, so that only a trickle of fuel is being dispensed. I make sure the pump nozzle is inserted all the way into the filler pipe, to allow the pump sensor to shut off the pump when the fuel level rises to full, to prevent any fuel spills. This method is identical to using a fuel can to fuel up, except the pump will shut off automatically when the fuel level is full. (It's not the same as topping off by repeatedly squeezing the pump at full speed, which would then have the potential to cause overfill and fuel spills.) I have been using the above method with 100% success. The only trick is to learn to squeeze the pump gently enough to have very slow fuel flow.

I do the same as above. Let it click off, then dibble in slowly for 3 to 4 more gallons. Sometimes I wiggle / giggle the car. I firmly believe in their efforts to curtail vapor emissions they do not allow the air to come out. Once you allow the air to come out, more fuel will go in. Typically we fill 11.5 to 12.5 gallons each fill up but it takes lots of extra time and is a pain in the as$.

GuruSQ33Z and Guru8GNYG assuming you both have 2019, my 2020 will fill up and show full but oy use 10 gallons before empty. So think the 2020 gauge is just wrong.

I think it is a combination of both. I have a 2019 but it is unlikely nothing changed for 2020. We just drove Los Angeles to San Francisco on one fill. In LA I filled slowly until I could see liquid pond and stay in the fill neck. In SF the fuel light came on. We could only put in 10 gallons. It was 403 miles. 40 miles to a gallon seems reasonable.

I meant to say it is unlikely ANYTHING changed for 2020. I'm 99% sure our cars are the same fuel tank wise.

After taking my car in to the dealer, they reported the fuel gauge is accurate and that they are aware of the fuel tank issue but don’t have a fix yet. They took my Toyota case number that I had gotten from Toyota the day before. They said to call back once and awhile to check in ... lol. After I drove off, I went to the gas station and filled until the pump clicked off, and then I slow-dribbled another 3 gallons in to get DTE to 510. Didn’t have the patience for one more! Lol

I'd be curious if anyone has tried to siphon the gas out of the car right when the gas light comes on. I am curious if that is 4.5 gallons or really the 2.5 gallons. Anyone have the time to try this?

Jpigott, I've done that by driving my rav4 until i went out of fuel. Took note of the milage when the gas light went on and continue to drive. It was in september with a warmer tempurature but i was able to drive 272 km or about 169 miles. A jerry can was ready to put back some gas. Driving with an avg of 40-45 miles per US gallon during this test.

I have tried the "trickle" method but I still cant get more than 10 gallons in. I have also noticed a drop in MPG since this has started. I was getting 40+mpg when the tank was filling and am now down to 36. Anyone else notice this?

Since the weather started getting cooler around October, my gas mileage has gone from 40 MPG to 37. I commute an hour each way and I live in the mountains so it is up and down. If I travel on the flat, I still get 40 MPG. I noticed the fuel tank issue the first time I filled up and it is quite annoying when you commute around 500 miles a week.. Otherwise I love the 2019 RAV4 Hybrid. Next fill up I'm going to calculate the amount of gallons it's allowing for a fill up.

I started a case with Toyota and this is what I got. Don't understand how it does not affect value. I would certainly would not have purchased it had I known it was a 9 gal. Gas tank.

I think we are averaging 34mpg even using eco mode for city driving. My 2020 xle tank shows full so I still think I just don't have access to the extra 4.5 gallons. I have tried to trickle in after it stops but haven't tried to trickle it the entire time. Will try this on next fuel up.

I think Toyota is playing games on this. I'd like to think they intend to fix it but I'm skeptical. If your state has weak lemon laws I suspect they will not be very forthcoming or helpful. Keep asking the service department to fix it.

I have a 2019 RAV4 Hybrid LE. Here are my observations about the fuel refill issue: 1) The tank does have a capacity of 14.5 gallons. 2) The low-fuel warning light comes on at around DTE=31 miles. 3) When the low-fuel light comes on, there is actually around 4 gallons of fuel remaining in the tank (from actual experience, which differs from the owner's manual). 4) If you are able to get in 10 gallons of fuel when the low-fuel light comes on, then the tank is full. 5) If you can only get less than 10 gallons of fuel when the low-fuel light comes on, the 'trickle' method can help to fill the tank to full capacity (but it must be a very slow trickle). 6) The 'trickle' method does not require filling the entire tank that way (would take way too long), just after the initial pump shut-off at regular fueling speed. 7) Toyota's are known for being conservative in when the low-fuel light comes on, so 4 gallons remaining is not unusual (but does differ from the owner's manual 2.2 gallons remaining). 8) The fueling issue is due to the tank not being able to vent properly at regular fueling speeds, causing premature pump shut-off. 9) The issue is likely due to different emissions standards in USA.

Toyota service said my gas gauge was accurate, and the problem was the fuel tank only accepting 3/4ths to 7/8ths to full before triggering shut off. I opened a case with Toyota, too. I also use the trickle in method to get the additional 3 or 4 gallons. Usually ends up spilling over a little, so I try to stop and check as I go. I can see the gasoline still draining as I take the nozzle out. Like the old funnels you used to use to pour oil in a car and have to wait for it to drain.

It began with my T.A. refusing to take the car in to check the issue of a not filling fuel gauge with level needle showing 7/8 when the pump (any station) clicks. Escalate it to corporate HQ. Got an interesting call from corporate Toyota Canada rep today. In short they are still in pure denial of the issue and are not willing to move a finger. His answers were 1- No issue with fuel capacity. The real usable capacity is 40L not 55L as advertised. Then some unclear explanation as to why there shall always be a 15L buffer in the tank that is not usable or great damages would happen to the hybrid system. Frankly, I dont buy this one. 2- The fuel gauge showing 7/8 when the pump click: Nope...it's normal... Not an issue, but... don't try to overfill pass that using a trickle method or you will damage your vapor canister.... Then a final mention that is seems that nobody raise this issue, or it would have triggered one of their issue surveillance commitee action... Well guys, let's open ticket to Toyota corporate HQ. Customer service phone is 1-888-869-6828

Here is the Tech Tip notice to Toyota Dealers

My 2019 Rav4 Hybrid XSE is having all the above problems and I opened a case with Toyota and they sent me back that there is nothing they can assist me with! No buy back!! Any advice?

Look up you states lemon laws. Keep taking it to the dealer asking them to fix it and document the problem. Thats about it. My State has strong Lemon Laws some dont. I have determined that the gas gauge is inaccurate and the mpg readings are wrong. I have to give them 4 chances to fix it.

Does anyone want to start a class action?

Hell YES I want to be a part of a Class Action! I'm one of the earlier 2019 Hybrid purchases and I heard it would take less than a month for Toyota Corp to find a fix. It's now been 9 months, and everything Corporate and my Dealer says is bullshit. They're not going to fix this problem. They're going to redesign 2021's and everyone who has a 2019 or 2020 is SOL. Unless we do something about it. I couldn't be more frustrated. I get about 32 mpg, and I can't go more than 350 miles before I need to fill up again.

Sign me up. I have a case number with Corporate and one with the Service Dept at my dealer. I contacted Toyota Corp and asked for compensation for the frustration I feel every week when I attempt to fill up a car that won’t let me put more than 7 gallons (in a nearly empty 14.5 gal tank) without clicking off. They asked if I want to pursue the Lemon Law as at this time that is all they can offer. I elected for now to wait. I am not yet ready to start the process all over again. However if a solution isn’t announced soon I will be returning this $45,000 car to which I added $1,700 clear bra because this was going to be my last/forever car!

MiloCat2019, Sign me up too. Let us know what info you need.

I did just get confirmation that my case is being reviewed by Toyota legal department in Chicago for my case that I opened with Toyota corporate 800-331-4331. Be firm ask for lemon law or repurchase option. Anyone in USA can also file a case at NCDSUSA.org this is a separate group that has no cost. I have not done this yet.

The biggest issue is Toyota's refusal to admit the problem. The dealers in USA knew in November as to the Tech Tip yet they seem to deny knowing anything. They are still selling the 2020 and it has to have the same problem (same tank). The Customer Service line says they know nothing yet they have access to the TT letter. What gives? Toyota should fess up to the problem and let the owners know in writing they intend to fix it. Absent that, Lemon Law or class actions are probably the only remedy. In every case I think we should go to the dealer and ask for repairs documenting the request.

Just got my letter from Toyota Corporate denying anything was wrong with my vehicle and closing my case. I have a 2019 XSE averaging 32mpg and 9.5 gallons in the tank. I have hired Lemburg Law to push for a buyback or swap for a new vehicle. I bought the car and upgraded for the mileage and the gas 2019 rav4 they loaned me while mine was in the service department is getting higher gas mileage then my hybrid. Cannot believe Toyota is still denying there is anything wrong when even the dealerships/service departments are admitting it now.

How many times did you take it in for service to have it fixed before your denial?

Great that doesn't make me very hopeful for my letter that should be coming soon.

My car went in 4x for these problems, additionally 5x that were undocumented, well over 20 emails to my service manager at documenting my weekly fillups since September, fuel receipts, distance to empty, 31- 33mpg average, 9.5 gallon fill ups etc. My dealership was shocked at my letter since there are so many issues my car has that has been documented locally and regionally with the Toyota dealership. I love Toyota but flatly denying anything is wrong with my car is beyond frustrating. The lemon law lawyer seems to think my case will be open and shut with how much details I've kept since purchasing, fingers crossed! Hard making these payments every month on this car knowing I'm getting the same fuel economy as the gas version$10k less then my XSE.

Ordered my Rav 4 Limited Hybrid April 2019 and finally received in Aug 2019. Fully loaded and with additional clear bra and window tint as this was to be my last vehicle for retirement. Have been to my local dealer for inspection and filed a case with Toyota Corp. Getting the same response as you all and definitely tired of the BS. 38 - 41 mpg and 550 mile range is what was advertised and and expected! Now 36 mpg, at best, with about 380 mile range after 11 k miles driven. Only fills up to 10 - 11 gals instead of 14.5 as advertised. Sign me up for class action law suit. I'm also pursuing lemon law or buy back option. What gives Toyota??? Very disappointing!!

Dont waste your money on lawyers! This is what I did: 1- took mine in the required 3 times (that’s what my states lemon law required) 2- called Toyota to open a case 3- Toyota rep would literally call me once a week 4- I finally got firm and told rep if they did not give me my money back that I would take this as public as possible (I am in public relations/media). 5- received call back that they were going to send to their legal department 6- less than week later had a letter offering to repurchase it. No need for lawyer, they know they are wrong they just expect most people to give up and walk away. More people need to do the above and be firm.

Cranberryion_1 did you get full price back or some calculated price per mile? Did they refund your state tax as well?

They refund you the price you paid including tax but do take off a pro rated amount for mileage and wear. They sent a third party out to inspect mine and looked at tire tread, interior and exterior etc. then once the lady did her checklist she handed me a check from Toyota and I turned over the title to them

I have been talking with my local dealer since I took the car in over a month ago to see if they were aware of the problem and knew how to fix it. They didn't but opened up a TAS case. Over the last month I have been asking for status updates - nothing. So I called Toyota USA yesterday. They took down all my information, including the TAS case # and called me this morning. They are well aware of the problem and have tried some fixes, mainly in terms of putting in a new tank, but also some sort of new part fix. Neither seems to be the final fix, but they said if I want to try that they are OK with that. I thanked them but said no, I'll wait until you get a permanent, guaranteed fix.

Fortunately if you are looking to have your vehicle repurchased or swapped and not asking for any financial costs associated then in most states including mine the lawyer does not cost the consumer a penny. So with my law firm I am not paying anything to them as I am not looking to ask for any money. It is really unfortunate about the mileage because I asked my dealership about putting miles on my car while i was waiting for the claims and making sure that anything would be based off of when I made the claim (we were heading on a long road trip) and I was still waiting for a response and did not want to put excess miles on my vehicle if I was about to get it re-purchased and have the amount dropped due to mileage. The dealership told me if would not effect anything. I will have to look back into this after reading your message @cranberryion_1

It would be great if someone was willing to post their letter from Toyota. It might help others with State arbitrations or claims to see exactly what Toyota is saying.

I agree with you @Olddawg If any has the letter from Toyota please post it. That would be very helpful. Thanks

Here you go! And I did this all on my own no need for attorneys...just knowing how to write letters and be firm!

Here is the info I was asked for from Toyota to send in. I added my video from youtube as well. I have called them today and asking how some people are getting paid and others are getting denied for the same issues. Anxious to see what my results are.

I am a reporter in Dallas TX working on a story about this issue and am looking for documents which support HOW LONG AGO Toyota was made aware of this. Please send your story to me at steve.noviello@foxtv.com ESPECIALLY IF YOU HAVE A DOCUMENT WHICH SHOWS YOU REPORTED THE ISSUE TO TOYOTA AND THEY ACKNOWLEDGED IT. We are trying to figure out how long Toyota continued to sell vehicles with which they knew there was a documented issue and didn't disclose that to future customers.

They are still selling them. The 2020's are having the same problems. Their customer service lines play dumb and they appear to not communicate via email.

Youll find that reports were made to Toyota almost as soon as the 2019 was released. Reports were made that Lemon's were being bought back as well. Dealerships were trying to fix them as well. Toyota National seems to know what repairs are being attempted by the shops. In November they released the Tech Tip. The dealers seem to be oblivious to the Tech Tip. Its as if they are all operating under a code of silence. Now there is a report that Toyota issued a statement that its the shape of the tank. Well all 2019 and 2020's tanks are the same. If its the shape of the tank, all of them have the problem. They have stopped changing the tanks. We are basically told to 'live with it" and there will be a fix coming. I have not seen this in writing anywhere. With all the stories Ive been told, I know longer trust them. Others are told there is nothing wrong with the vehicle even though the range is not as advertised, the mpg seems off and the tank wont fill or the fuel gauge if inaccurate. I have tracked mine and there is a 2.3 to 2.5 gallon discrepancy.

I had my 2019 XSE's tank drained when the fuel gauge read "E" and was told by the dealership tech that 2.5 gallons were removed. That was put back into the tank and it then took 11.82 gallons to reach "F" on the gauge. I then drove 23 miles past "E" and filled it up. I got 10.6 gallons before the initial click off, then force-fed it through a few more click-offs til i got a total of 12.18 gallons into it - meaning I still had at least 2.5 gallons of unrecorded fuel when the gauge read empty. ad 2 gallons whe I pulled up to the pump with my gas gauge needle pointing to a blanspot abut 1/8 inch below the "E" mark, This probably means that most of us with the problem can safely drive 60-80 miles past empty before really needing to pull into a gas station - although that's not a fix, just a thumb in the dyke for those who routinely push the limits between gas stations. What I don't know is whether the tank, if really emptied out, would still only accept 10-11 gallons before back-pressure shut off the nozzle, or whether a really empty tank would actually accept something close to 14 gallons.

I fill up when the fuel light comes on. Based on the vehicle specs I should have 2.2/3 gallons left. The mileage to empty usually shows 26 miles. I should have a reserve covering 80 miles (roughly). The problem is I cant put in more than 10 gallons. This 2.3 gallons are missing. This means either the tank is really full and it has 4.5 gallons in reserve or the computer is wrong (reading less than full and inaccurate range) or the tank wont fill up. Either way something isnt right.

I bought mine in July and I have documentation fairly soon after that from corporate acknowledging the issue. I took in for service in November (tire rotation) and the tech either played dumb or wasn’t told that gas tank is an issue with hybrids.

After the pump clicks off and I have a DTE of about 380 miles, I can put another 3-4 gallons in via the slow-trickle method before it overflows to get the DTE above 500 miles.

So I contacted Toyota national for an update on a fix. Needless to say their response was zero. They said they provided me with Toyota’s “position” previously. That’s a complete lie. I’ve been provided with nothing and for sure nothing in writing. At this point I guess I’ll have to start the lemon law process. This is my 9th Toyota and probably will be my last.

So what should we do? Is that possible that they can just ignore our defected cars and have us live with it? I am running a case with NCDS and the hearing is in Feb but Toyota’s representative is being completely dishonest about it and replying “the Vehicle is operating to manufacturer specifications and does not impact the use, value or safety of the vehicle”!! Any success stories through NCDS?

To this question. "So what should we do? Is that possible that they can just ignore our defected cars and have us live with it? I am running a case with NCDS and the hearing is in Feb but Toyota’s representative is being completely dishonest about it and replying “the Vehicle is operating to manufacturer specifications and does not impact the use, value or safety of the vehicle”!! Any success stories through NCDS?" get the materials from toyota stating they have a 500 mile range. Your owners manual has the tank capacity and says the tank has a 2.2 gal reserve when the gas light comes on. Mark these documents and take them with you. Now when the fuel tank light comes on, take a photo and then fill the tank. find your missing 2 + gallons. Either the tank light is broken or the tank isnt holding the right amount of gas. Either way its defective and they need to fix it. Take with you the reports that toyota has acknowledged there is a problem and the TT service report which has been posted. Their statements dont match their own service advisories.

Not sure if this is helpful still but here is another video from tonight filling up the 2020 Rav4 Hybrid XLE with estimated 15 gallons left. The needle was not even to the E it appears. https://youtu.be/qD9IaqXF9YI I did the "burping method" after it clicked off at 10.5 gallons I bounced the car from the tailgate for 30 seconds then trickled more gas in, repeating this 5 times I was able to get to 13 gallons and I stopped as I didn't know how far I should go and it did not over flow. Could I have added another gallon? It showed an estimated range of 466 miles after I was done. This car is also only getting 30mpg for local in town 35mph. Still awaiting final Toyota letter from thier legal team.

UPDATE: We have made contact with the Chief Communications Officer with Toyota- they are, so far, declining our request for an on camera interviewing. While they have sent a statement - they have also asked if we have a specific question. Here's your chance- IF YOU HAVE A QUESTION FOR TOYOTA SEND IT TO ME VIA EMAIL Steve.Noviello@foxtv.com

YOUR VIDEO OR SKYPE NEEDED- we are trying to document as many of these cases as we can. If you are willing to send me a video (cell phone is fine) explaining your issue PLEASE CONTACT ME VIA EMAIL steve.noviello@foxtv.com

Question: Will Toyota commit to fixing these defective vehicles?

Question: I have documented 4 months of fill-ups, pictures of MPG and been into my local dealership 5 times with them even admitting something is very off about my car but received my claim letter that Corporate Toyota is closing my case due to nothing wrong with the vehicle. If it is not a safety concern then it should be false advertising. If I expected 580 miles a tank and 38-41mpg based off the sticker on my brand new vehicle and i am getting 30-33mpg and 300 miles a tank... if I was going to keep my Rav4 Hybrid for 200,000 then I am looking at an increase in fuel costs of roughly $18,000 for a vehicle that gets the same or under what the gas powered version does. I guess there really isn't a question because I am still in shock they will not admit to wrong doing. But I feel like it is not going to fall under safety for Lemon Law it would be false advertising and the car not doing what it says it will. Is that what will make them pay attention - enough people realizing how much money is going out the door on a vehicle you paid top dollar on to save on fuel costs?

Apparently, Toyota in Manhattan Beach found the issue with the tank. Not enough ventilation; therefore the nozzle shut off at 10 gallons. They advised to remove the nozzle after the 10 gallons and wait 30 seconds and try again. Then it will fill up the remains 4 gallons. They swapped the tank but it does the same thing. Pero the dealer, Toyota needs to reconfigure the tank and change it to fix the issue. However, based on The lemon law and my attorney, I’m getting a full refund, including tax and license. Since my car is less the 1500 miles, they are not prorate the mileage, they’re buying back the car . I received a letter of the breakdown (provided receipts of the Toyota accessories I bought) I was told to let them know what dealer I would like to take the car, once I do that, my check will be ready for me at the dealer.

Taking my car in to Toyota in a few days. Any tips on what I should bring up. Seems I have little hope of anything really happening, but to start documenting the issues.

Dont be shocked if they claim lack of knowledge. Documents and a good lemon Law may be your only hope.

The question is, is this occurring on ALL redesigned ('19-'20) Hybrids, or just a portion? I stopped by my dealer last week and the sales team had absolutely no idea that these issues are plaguing these Rav's. I had been on the fence concerning legal action, but if Toyota wants to play this game, then game on.

https://topclassactions.com/lawsuit-settlements/consumer-products/auto- news/toyota-class-action-alleges-rav4-fuel-tank-defect/

Hey steve.noviello@foxtv.com - if you could post your article here, or a link to it, once it's published, that would be appreciated by all of us I'm sure. Very curious about the end result and if your article will eventually help all of us in any way. Thanks for all you do!

Hi all- thank you for all of your input and those of you who sent in videos. Our story runs on FOX in Dallas tonight- but for those of you outside of that news market I have set the video to run live on facebook.com/savemesteve tonight at 9:29 CST. I will post a link to the story on our website tomorrow, but if you want to watch tonight, my facebook page is the best place to do it.

Here’s our report. Please be in touch with your updates. Steve.noviello@foxtv.com https://www.fox4news.com/news/consumer-alert- gas-tank-design-flaw

My original post for my news 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

We just posted a follow up. Toyota now offering to replace gas tanks for everyone but they can’t guarantee it’s a forever fix https://www.facebook.com/160050740695958/posts /3068919376475732/

For those of you without Facebook here is a web link. We just posted a follow up. Toyota is now offering to replace gas tanks although they cannot guarantee it’s a forever fix. https://www.fox4news.com/news/toyota-offers- interim-fix-for-rav4-hybrid-gas-tank-concerns

Interesting to see Toyota offering to replace the tanks as an "interim" fix. Has anyone previously had the tank replaced and it actually worked? Plenty of posts saying the tank replacement made no difference.

https://www.fox4news.com/news/toyota-offers-interim-fix-for-rav4-hybrid-gas-tank-concerns

Replacement of gas tank DOES NOT WORK!!!! My friend and I bought a RAV4 hybrid 2020. We flip the coin to see who does it to see if works.... when we went to a gas station after replacement, the same thing happen. We went back to Toyota and they said. “Well, You need to wait until we can figure it out, it worked on some hybrid” that was just a lie. Don’t do it or waste your time. Still working on the buyback from Toyota. I sent all my documents and they still asking for a payoff letter from the bank... 3 weeks later they called me back and requested another one since my letter expired. Already provided this letter 3 times. The call won’t be from me, it will be from my attorney. So disappointing how Toyota handled everything. Never disclosed this issue at the time of the purchase! Wondering if the RAV4 plug in will have the same issue?

Just got this email, anyone else ? "Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2020 Toyota Avalon Hybrid, Camry, Camry Hybrid and Lexus ES300h and 2019-2020 RAV4 and RAV4 Hybrid vehicles equipped with 2.5L 4-Cylinder engines. Porosity in the engine castings may result in cracks than can allow coolant to leak internally and/or externally."

Has anyone done the buy back process? How did you go about doing it and what's been the results. I had the tank replaced last week at the instance if toyota and it didn't wilork.

Mine was bought back in October 2019. You just have to be firm, make sure you have taken the car into dealer at least 3 times (depending on your state lemon law) for the same issue with no resolution. You just have to demand that they purchase back the vehicle and be persistent.

Cool thank you Cranberryion_1. My case manager from toyota is calling me back today. Here is what I have went through so far. I bought my vehicle at the end of July 2019. I filled up two and a half weeks after the initial fill up which the dealership put in 569 miles I only got around 500 miles. I texted my sales guy and asked him about it and never responded back. I still have the text.I got a case number from Toyota Corp around September of last year. I went to my dealership in September of last to have them look at it after I saw all the complaints online and they ran a sensor test and found nothing wrong. They basically ignored my compliant.The 2nd time (5,000 miles service) they told me nothing was wrong. The 3rd time I went in was December they said there was an issue and they heard about it and were waiting on a fix from Toyota and said I needed to wait to get a letter. I had the gas tank replaced at their instance last week. That was my fourth time and replacing the gas tank did not work.

Yep you've got the documentation now you just have to be firm and let them know that you are done dealing with the back and forth and demand the repurchase otherwise you will have to seek "third party involvement" and go to the press, media etc.

Thanks!!!

I received my letter back today. DENIED!!! NOT SURPRISED total scam. Any recommendations... This was 2020 Rav4 Hybrid XLE.

What state are you in?

@steve Illinois.

I would go after them using your states lemon law and a complaint to the attorney general. http://www.illinoisattorneygeneral.gov/c onsumers/lemonlaw.html Your car is unsafe as you have an inaccurate fuel gauge. You have no idea how much fuel is in your tank. When it hits the fuel light it should have 2.2 or 2.3 gallons or zero. You can be stuck by the side of the road. The attorney general should be concerned they are selling these cars with a known defect.

A link to the class action complaint is below. https://www.classaction.org/media/ly-v-toyota-motor-sales-usa-inc-et-al.pdf

Having the same issues as everyone 32-33mpg even feathering it and only getting 350 miles to a "full" tank. In washington state and bought the car 3 weeks ago.

Just to point out some misconceptions about the fueling issue with 2019/20 RAV4 Hybrids (in US/Canada): 1. Gas gauge operation and accuracy are not affected. Eg, the gauge won't show full if it's actually empty, etc. 2. MPG is not affected. If you're getting very low MPG, it may be due to very cold weather, or other reasons. 3. It's not a safety issue, other than trying to top off and causing a fuel spill (which is recommended against in general). The fueling issue is strictly the gas tank not venting properly at normal fueling speeds, thus causing the pump nozzle to shut off prematurely before tank gets completely full. Toyota has indicated this is due to gas tank shape (geometry).

Even when the weather is warm and I reset my MPG gauge and drive as easy as I can i'm still only getting 33ish mpg. I've also heard of several others getting the same thing in warm weather cities. It seems more like the MPG issue is a case by case scenario and the fuel tank issue is more encompassing. I may be completely off base though as i've only owned my vehicle for 3 weeks and am not sure if there's some sort of break in period.

I live in SoCal, and have had my 2019 XLE up to 35.5 mpg at 7 months after purchase. I'm currently at 34.9. Personally, I love the car and wouldn't even consider a buyback. Yeah, gassing up is kind of a pain, but I just follow the trickle method and manage to get ~450 miles to the tank.

I thought I saw a post before with a lawyers number who has helped another member here with the buy back... Anyone recall seeing that?

So, I thought I'd put my 2 cents in about people saying there is nothing wrong. 1) You sound like you are a toyota rep that is trying justify the issue at hand and 2) I have lived in the same city my whole life and never have I experienced that far off of a mpg rating...and I have owned a prius and a yaris before. I have ALWAYS exceeded the mpg rating because of my economic driving for any car I have owned, so much so that I have even gotten 70 mpgs out of a pruis! I have lived in Missouri all my life and sometimes temps get into the negatives, yet still I'm only off by about 2 mpgs in the worst weather...but this RAV4 I bought has yet to exceed 38 mpgs (and mostly sits at 36 mpg with my economical driving) total which is the minimum mpg "possible" for it so it is clear there is something up. I cannot put more than 10 gallons in even on literal "E" and I did a bunch of calculations to decide if I wanted to afford this vehicle, one of which being that I could go further on a tank of gas and it would cost me less money overall to own this vehicle. However, now it is actually costing me more than my last vehicle (Mazda CX-3) because it takes more, in the sense of a total volume, in the tank even with the defect to fill up and goes about the same distance as my mazda did...but costs me literally almost double in payments. It is very frustrating for people who do not have a ton of money to spend and see this as just an inconvenience as opposed to people who weighed their options and spent more money because the benefits Toyota was touting. I honestly just want my vehicle fixed...it's the least Toyota can do since I spent so much money on it.

I own a 2019 XSE Hybrid. I bought it in August. I'm getting around 36 MPG highway. I live in the Blue Ridge mountains and travel the interstate 120 miles a day so it is up and down hills. If I travel on flat rural roads, I'll get 39 to 41 MPG. I have noticed that cold weather does affect the mileage. The gas tank is a definitely an issue. I cannot fill up totally which is somewhat of a pain. Otherwise I love the car.

I just talked to another Toyota dealer who said they spoke to Toyota about the 2020 issue yesterday. He said they admit there is a problem and they are working on a redesigned tank. If anyone is getting a replacement tank now it is the existing tank which won't solve the problem.. He said that they will not do buybacks typically if they know a fix will be coming. If not he said we would have a good case to try. I also mentioned the 27mpg that I am averaging and he said it so the cold weather and then said since I only have 1800 miles on the car there is a "break-in" period of 3000iles where it runs richer. Not sure if that last line is true or not.

We purchased our 2019 RAV 4 Hybrid Limited for Toyota’s reputation with hybrids. Noticed gauge not showing completely full months ago and was going to mention it when next service was needed. Have kept complete fill up records since purchase. Husband was able to get 11.3 gal in with trickle method. Have a case number after talking with Toyota corporate. Taking it to dealership on Monday to “get problem on record” as case manager put it. I asked the service person what will be done that takes one to two days and she said they pull the tank to replace the sensor. I told her I thought we were merely bringing the vehicle in to officially record the problem. Case manager seemed agreeable at corporate when I talked with him but did use verbiage quoted from something Toyota posted online I’d already read about “mitigating” problem. We’ll see how things go on Monday. Thank you all for illuminating your problems.

Cranberryion_1 I know you previously told us what you did to receive the buyback of your vehicle. Is there any way that you can let us know what paperworkyou submitted? Did you write a letter, what buzzwords did you use for them to send you the letter that you got. I got my letter from them the other day and I am getting all my paperwork together but I want to make sure that I have all the information that is needed.I want to let them know I mean business.

You Don’t need a letter. Once you file your claim with Toyota, they will assign it to a case manager. The Manager will ask you questions regarding the issue with your car. You will tell them that since this is an issue that cannot be fixed it will consider a lemon car (depending on your state law” you need to mention that Toyota failed to disclose this issue when you bought the car (Toyota sent a notice back in November) in addition this false advertisement since you are not getting the mileage that was stated on the sticker price. You are trying to resolve this issue yourself or they will get a call from your attorney. Once that conversation take place, They will call you in few days and request All the paperwork from the finance company, bank, credit union, whoever financed your loan, you need to provide them a payoff letter for 4 weeks since it make Take that long to close your case. Later, a 3rd party company will call you to set up a date and time to surrendered the car at that dealer you bought the car. They will give a check to payoff your car and a separate check for your down payment including any money you spent on accessories (of course, if you bought from Toyota, non after market parts) please note, on the first call they ask you what’s the mileage on the car, once you confirm that, you can’t go back, they will deduct the mileage, but after your case is confirm, you won’t get charge for any additional mileage. I got all my money back, less $205 because I said that my car had $700 miles at the time I reported the issue. I hope this helps.

I got my denial letter after a week of toyota sending my first letter. They didn't give me any opportunity to send in my information. Anyone have any either ideas. I am not happy right now. O never got a chance to present my side. This is so frustrating!

GuruRM653 I am betting everyone will going forward if they are working on the new tank...

What I don't understand is, if our problem really is due to the shape of the tank, why aren't ALL 2019s experiencing this problem? Some here have reported in that the problem isn't occuring on their cars.

I think some people are just not as informed about it. I met a person playing golf and asked if they have issues with gas filling or only 10 gallons and they said yes. But hadn't thought to call their dealer. Or they think they just have to wait for a recall notice.

I think the reason some 2019/20 RAV4 Hybrid owners are not having fueling issues, despite having the same fuel tank shape, is because the gas pumps that they are using (on regular basis) dispense fuel more slowly compared to others. The slower fueling allows the tank to vent better and get close to full (even if not completely full), so the problem is not noticed. That's also the reason why the 'trickle' fueling method works. The gas pump nozzles are designed to shut off automatically when the fuel level slowly reaches the tip of the nozzle (so I have not experienced any fuel spill issues using this method). It's only when you repeatedly squeeze the pump handle at full speed that overfilling can happen.

I'm told they all have the problem. Most people are not paying attention. I might add for folks to check the "miles to empty" as it has also proven inaccurate. I can get the tank to "fill" but actually it isn't. The tank will show 460 to 480 miles but actuality it will only travel 400 miles (+/- a few) at 38.9 mpg. It acts like a 10 gallon tank. There is no way that all with the same tank don't have the same problems.

I received full reimbursement check today (monthly payments, accessories, insurance, personalized plate - submitted all my receipts) Toyota will overnight a check for the current balance to the credit union. This process took 2 months. I finally surrender the car at the dealer and after checking the tires, interior, exterior, they gave me a check for the full amount of all my receipts. Right away they post a paper on the windshield “car will be sold at auction”. So sad to see this baby go, hopefully the RAV4 plug in won’t have this issue, looking forward to but in the summer.

Anyone heard any updates?????

I was told by Toyota National a fix was coming at the end of March. I don't believe them. I asked service about the tank swap and they did not recommend it saying that it was not likely to change anything.

I haven't heard anything either. I took my car for service in February and all they told me was there will eventually be a fix. Unknown when.

I also have the fuel tank issue on a 2019 rav4 hybrid and cant fill more than 10 gallons. dealerships refuse to test and record the issue in documentation to avoid a possible buyback. Corporate is avoiding any responsibility. given that Toyota knew about the issue from the start and it is now more than a year with the 2021 coming soon to dealerships I don't see a real fix coming until the collective class action lawsuit is finished. Given several other issues with the vehicle (battery, transmission), I would recommend avoiding purchasing Rav4s at this point.

Any updates?

Just learned I might have other issues besides this gas issue. Guess I need to go to the dealer to check the serial number of the engine now since my car was built during the time mentioned. https://www.caranddriver.com/news/a30997060/2020- toyota-recall-camry-avalon-rav4-engine-cracks

Endless lies. Told me the fix would be out over a month ago.

Just received a letter today from Toyota (Plano TX) labeled Customer Support Program Interim Notification. They acknowledge the "vehicle refueling performance" condition. No recall at this time; repair is forthcoming; another letter will be sent once repair is available; contact dealer or Customer Experience Center with questions.

I received the same letter saying they are increasing the warranty on the fuel tank to 8 year 100,000 mile. Makes me wonder if they will ever do a fix here. The paper work showing how much is really usable in the car was less than helpful.

I just purchased a 2019 toyota rav4 adventure (non-hybrid) and have noted this issue within the first day of driving. Will file complaint and contact dealer on Monday. Very disappointing.

Wow this is the first I have heard of a non hybrid with this issue. Toyota has reported they are working on the fix, but will be interesting to see when it comes out.

Well Toyota still have no fix and customer service says there is no ETA for a fix. If you have the problem you should probably Lemon Law them is you can. Toyota is giving us all a runaround now for well over 18 months. I wonder if they ever started telling buyers these things were defective.

So the fix has arrived. Toyota fixed mine about a week ago. The fix involved a new tank and sending unit. When I received the car back it has the Distance to Empty at 490 miles. I drove the car until the fuel light came on. The light should appear when there is 2.5 gal left in the tank. The Distance to Empty read 26 miles. It filled the 12 gallons without having to click off the nozzle 20 times. The fuel gage read full and the Distance to Empty read 497 miles. Since the fix my driving has not changed but my mileage has gone from 40mpg to 36 mpg. Makes me wonder if it was ever accurate in the first place. The Distance to Empty also seems off. It must not calculate the 2.5 gallon reserve so you have another 70 to 90 miles when the Distance to Empty reaches 0. Thats a lot of driving. I dont have the guts to drive it to empty to check that theory.

Toyota bought the car back 9 months ago. They told me to wait until the RAV4 Prime get release by the end of the year. They put me on the waiting list as a thank you for all the trouble. Just got the call that the car was arriving 12/12/2020 but it is the XSE with premium package. I’m not paying $54,000 for a RAV4. Even with $7500 rebate.

Olddawg, did they contact you for the fix or did you have to contact the dealership? Thanks for the info. I don't have the fix and it shows I average 38.2 per gallon.

I had called Toyota national. They told me it was released several weeks back. I called the dealer and they confirmed. Took about a week to get the parts.

Toyota is sending leters to all those who registered complaint with customer service..the fix can involve a new sendinfg unit, a new sending unit and a "fuel tak sub-assembly,' or a whole new tank and/or sending unit. Depends on what exactly the problem is. For my 2019 XSE Hybrid (in SoCal) the fuel indicator didn't show completely full when gas delivery hose clicked off, and I could only get 9.5 gallons in before it clicked off. Dealer put in new sending unit and tank sub assembly. Distance to Empty readout changed immediately, but I'm still waiting for low fuel light to come on to see how much now goes into tank before hose clicks off. If under 9.8 gallons (Toyota's stated cutoff) I'll take it back fora new tank.

I have an appointment Monday to get the new redesigned gas tank installed. They said it would take 2-3 hours to complete. Hopefully this will solve the problem.

My car was repaired 2 weeks ago: sub assembly and sending unit. They took my car in at 7am and called me at 12:30pm it was done. The gage showed PAST full. Between COVID lockdown in CA and it being a hybrid - I won’t need to “test” the fueling until mid-January if then!

I’m on my third fillip and they seem to top off at around 470 miles to empty. Gas mileage has reduced to about 35 highway or a 5 mpg reduction from before the “fix”.

I am curious what people find out on the Rav4 Hybrid 2020 as it showed past full, and would only get 35ish mpg in town but couldn't get more than 418 without over topping off. Took mine in today to do the first step inspection before they order parts. So waiting to here when the parts come in now. Will post after I know more, I told them it should be over 544 miles on the estimator.

I got the "fix" at my dealership. I will know more if it worked on the next fill up. When they filled up at the dealership it got 502 miles. Before the fix I was getting 440 miles. I will note that the mpg is doing better since the "fix ". I drove 27.5 miles to my job from my dealership and only used up 20 miles of gas.

First fill-up after fix for my 2019 XSE Hybrid of new sending unit and fuel tank sub-assembly (not entire new tank): Took 11.6 gallons to first automatic pump shutoff and a added 0.2 gal after that for total of 11.8 gal. Was filling from low fuel light w/13 miles indicated remaining range. Gauge showed slightly above full and 414 miles range after fill. My lifetime fuel efficiency average is 31.9 mpg (I have lead foot and have to drive up a miles of very steep, fuel-sucking hill to get home).,

After the fix I thought I lost mpg. After filing twice and checking numbers it seems that the tank average mpg is now inaccurate. While it says 36.7 I’m actually getting slightly more than 39. Prior to the fix, it was correct.