What 869 owners told NHTSA about the 2019 Toyota RAV4 Phev

The vehicle suddenly started to smoke and burn by itself when driving on the super crowded highway. I immediately stopped the vehicle and found that the burning site was the bottom of the front-left head of the vehicle (please see the images attached). The mechanician I visited after judged that the fire may due to failed electrical parts or system. He suggested to visit a Toyota dealer for recall. However, the Toyota dealer (Crown Toyota, 1201 Kettering Dr, Ontario, CA91761) declined my request with the reason that my vehicle has passed warranty time. The vehicle was just inspected in the Toyota dealer a few days ago. The dealer's inspection report shows that the vehicle does not have any problems besides suggesting to replace tires and front brakes.

NHTSA ODI 11632904

The Data Communication Module has failed in my vehicle. This causes several major distractions and increases the risk of an accident. The media screen in the center of the dashboard will send an alert message every 15 seconds saying that ‘the connected device is not compatible’. At night, this alert message is especially bright and distracting. The lights on the SOS button are constantly blinking. More significantly, the SOS button does not work anymore. The only known solution to this problem is either to disconnect the DCM, or to pay more than $1300 to replace it.

NHTSA ODI 11631969

I am writing to file a formal complaint regarding a manufacturing defect in my vehicle and the refusal by Toyota to honor its responsibilities for repair despite clear acknowledgment of the issue. In October 2024, I discovered a small water leak from the roof of my vehicle. I attempted to schedule an appointment with the nearest Toyota dealer, but the timing of their available appointments conflicted with my work schedule, and it was not possible for me to get a timely appointment. In an effort to mitigate the leak, I tried to fix it myself until I could get the vehicle to the dealership. Upon visiting the dealership, I was informed that the issue was a manufacturing defect, but they refused to repair my vehicle because I had attempted to fix the issue myself. This worsened the leak, as they did not return my vehicle to its original condition. I was then informed that I would have to bear the full cost of repairs. I had no prior knowledge of any recall associated with my vehicle. After conducting my own research, I discovered that Toyota had acknowledged the manufacturing defect affecting my vehicle model but had not notified me or issued a recall. I reached out to Toyota’s customer service, and they assured me that they would approve the repair through the dealership. However, after approximately a month of waiting, Toyota informed me that they would not cover the costs of the repair, and they declined to take any further responsibility.

NHTSA ODI 11629392

My car frame floods every time it rains. This flooding includes my sunroof drain clogging. As a result of the water retention in my car’s frame, my cars safety system controller units are being corroded and thus I DO NOT have any reliable safety monitoring system. I have looked into this and this a COMMON complaint for Toyota 2019-2021 Rav4 sunroof cars. I have had the sunroof drain cleared multiple times but the issue remains. So far it has impacted my tire pressure safety monitoring systems. This is a MAJOR safety issue as the electrical safety monitoring system controller units are NOT properly functioning as a result of poor water drainage.

NHTSA ODI 11629224

I have been told by the Toyota Arapahoe dealer that the DCM in the car is bad. All the services the DCM supposedly provides have NEVER worked on the car, leading me to believe it has been faulty from day one. These include all safety assistance features.

NHTSA ODI 11625508

Initially thought a seal on the windshield was faulty, so contacted the business who replaced the windshield. Business owner came to owner’s house Mon, Nov 4, 2024. He did a thorough inspection of all areas where water was identified by owner (dash, under the dash, on the driver side floor) and confirmed it was not the windshield. He then inspected the roof rack and determined the roof rack was defective and leaking water from the ceiling of the vehicle, down into the dash, and ultimately onto the floor. He recommended contacting Toyota because this was a known issue. By 12pm on Mon, Nov 4, 2024 owner contacted Toyota alerting them to the issue. An appointment was made to bring the vehicle in for inspection on Mon, Nov 11, 2024. Owners do not have a garage or carport, so a canopy was pitched over the car in an effort to prevent any further water damage and moisture absorbing canisters were placed in the car. The vehicle was not driven in the rain during the period after first noticing the leak and bringing it in to the dealership. Evidence of Electrical Damage: On Friday, November 1, 2024 the driver side seat became extremely hot, to the point of needing to pull over and turn the car off. The seat heater was not turned on at any point during this time. On Saturday, Nov 9, 2024 and Nov 11, 2024 while driving on the highway, the car (normally driven in Eco Mode) unexpectedly switched into Mud&Sand mode and all safety features switched off. Owner was unable to manually override this occurrence. The “Normal” button did not work. After a few minutes, the vehicle switched into the default setting and owner was able to put it back into Eco Mode. On Nov 11, 2024 owner brought vehicle into Toyota for diagnostics. Owner requested that the electrical components also be inspected and was told it was not covered under the Customer Support Program.

NHTSA ODI 11624987

A distracting message “a connected device is not supported” flashes on my console screen every 10 seconds. This occurs when there are no device or cable connected. It blocks the clock and driving directions if I am projecting them through CarPlay. The SOS emergency system lights flash back and forth from red to green.

NHTSA ODI 11620818

Defective coolant bypass valves on my 2019 Toyota RAV 4 have caused coolant to leak out of my vehicle’s closed-loop coolant system, harming its ability to properly regulate engine temperature. Eventually the message “Engine Maintenance Required Visit Your Dealer” appeared on my dashboard indicating an issue with the engine. An internet search of this error message on the 2019-2023 Toyota RAV4 and Corolla models shows this is a widespread defect, affecting hundreds of Toyota owners. A class action lawsuit has been filed against Toyota regarding defective coolant bypass valves in the 2019-2023 Toyota RAV4 and Corolla models [XXX] et al. v. Toyota Motor Sales, U.S.A., Inc) but Toyota has still not addressed this defect with a recall. Attached is a copy of the mechanic invoice I just paid to replace the defective coolant bypass valves on my 2019 RAV4 as the engine was not maintaining temperatures appropriately and in risk of total engine failure. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11613162

SUV showed on the display that there was a Hybrid System Malfunction. SUV is in a Toyota dealership shop in Aberdeen, WA. I called the shop immediately when the notification came up. Was advised that it was OK to drive until check engine light came on, which it didn't. I only drove to work amd back after the notification and call to shop. The cruise control would turn off and I'd be notified on the screen. Again was told ok to drive until check engine light came on. Approx a week after calling shop, SUV would not start before going to work. Had to be towed to shop. Potential safety issue if this happened while driving on highway or while in a rural/wooded/off main road area with no cell phone service. I was told my the shop that another SUV had recently had the same issue. Shop says that the wiring harness is exposed to the elements as built by Toyota. Has not been inspected by anyone but the Toyota dealership service dept. No warning ahead of time, just a notification while driving that there was a Hybrid System Malfunction amd then a Cruise Control Malfunction.

NHTSA ODI 11594402

My rear backup camera has intermittently worked for almost 2 years now. I was not included in the recall Toyota K05 / NHTSA campaign number 19V576, but I do believe I should be included as the issue describes the issue I have been having. Dealer advised me I need a new camera but the camera works from time to time. The dealer could not replicate my issue in Oct 2023. I’m still having the issue and it has gotten worse.

NHTSA ODI 11593961

“Engine maintenance required” maintenance light on dashboard. Very common issue within RAV4s. This message blocks the odometer on the dashboard when visible. It shows warning lights on the display as well. The part that needs replacing is a “coolant bypass valve”. My dealer wanted nearly $1000 to replace this part, and told me this part was on back order nationwide. My car begins to overheat after 1.5 hours of driving. The dealer said to pull over when operating my vehicle and it begins to overheat. This problem is an inconvenience as I commute to work in a busy city. This problem was first presented last week after my scheduled oil change with my local dealer. The next day (5/17/2024) the light came on my dashboard—unable to be removed. I first brought it into the dealer for a diagnostic on 5/20/2024, this is when they diagnosed a coolant bypass valve. I brought it back to the dealer today (5/23/2024) to have the part replaced, and was told it was on back order. I am afraid to operate my vehicle for long periods of time due to this issue. It has become a major inconvenience in my personal life this week, causing me to call out of work twice. This needs to be addressed by Toyota immediately.

NHTSA ODI 11590460

Coolant Bypass Valve leaking onto electrical systems. If not fixed, electrical system will fail. Toyota is aware that it's a common problem.

NHTSA ODI 11581168

The vehicle is a 2019 Hertz rental RAV4 Hertz. On October 12, 2023, when I moved the gearstick to reverse the vehicle accelerated uncontrollable at extremely high speed and crashed into a wall. Braking did not stop the vehicle.

NHTSA ODI 11559958

Car is shaking when turned on. Will stall if car is not shifted to gear sometimes. When AC is on, car will jump rpm. car acceleration is weak and will jump to 5-6k rpm. car also smells burnt sometimes when driving. car also smells like gasoline sometimes. car does not hold proper amount of gasoline.

NHTSA ODI 11555772

My car ran a message of “ Maintenance engine required” and it turns out the COOLANT BYPASS VALVE has gone bad. When turning the AC on the message appears, but went off the message doesn’t appear.

NHTSA ODI 11555738

Hybrid Harness Malfunction. As reported on FaceBook by my wife to [XXX] of LIA Toyota: "Well my husband's RAV 4 wasn't safe and you knew it. And corporate knew it. You are in the business of saving lives by informing your customers when you find a defect in your cars. This faulty harness is dangerous. And the repair is costly and there aren't many of these parts available to make the repair. You put my husband and countless others in danger. Shame on you." Not only has the problem been confirmed: On May 11th, I received a letter from TOYOTA Motor Sales, USA, Inc. entitled, Certain 2019-2022 Model Year Rav4 Hybrid Vehicle (AWD Only) Coverage for High Voltage Floor Under Wire Harness and Rear Traction Motor Cable Corrosion CUSTOMER SUPPORT PROGRAM 22TE09 NOTIFICATION... There was a YouTube Video made by [XXX] about this problem A YEAR AGO entitled, "CableGate," AND an article at TorqueNews. (I have links if needed) The vehicle has been inspected and repaired by LIA Toyota in Rockland County. OVER $5,500 that I'm looking to get a FULL refund. LIA gave me back $1,000 for over-charging me. I want the FULL refund from Toyota Motor Sales, USA, Inc. A warning lamp/message appeared on May 6. I have emails, reports to corporate & screenshots of conversations with LIA service...all lasting almost 2 months. Toyota Motor Sales, USA, Inc. and LIA Toyota BOTH new of this problem a year ago BEFORE they sent out the letter. The letter states they would repair it for free if under 100,000 miles. I had 114,000, BUT...if I knew a year ago, I would have brought it in...UNDER the 100,000 miles, and got a FREE repair. Thank you for helping me get a full refund and for helping others with this same problem. USA Toyota owners NEED TO KNOW THIS! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11541805

Engine Maintenance Required light came on. Got it checked out by Toyota Dealer and the coolant bypass valve needs to be replaced. It seems to be a common problem with RAV4s.

NHTSA ODI 11540885

The DATA COMMUNICATION MODULE - the DCM does not work properly. At first the Mic for the phone did not work when using the phone , then my clock and information page on the screen went in and out. I went to a dealership and they charged me $150 for diagnostic and now $1300 to fix. This is a vital piece of equipment for using communication devices hands-free. There is already a campaign to 21-22 RAV 4 models, and I believe this is the same issue only to the 2019 and 2020 also. Here is the link to the campaign. Please help me. https://www.toyoheadquarters.com/threads/2021%E2%80%932022-toyota-vehicles-dcm-data-communication-module-reprogramming-special-service-campaign-ssc-22tc01.2566/

NHTSA ODI 11532528

Vehicle is switching to mud and sand mode on its own, which according to a quick google search is a common electrical problem. Possible cause listed by other drivers is a roof rail leak. Upon inspection I see water stains on the inside of my headliner where the roof rails sit. So confirmed roof rail leak. I have not yet had this looked at to learn the full extent of the damage.

NHTSA ODI 11527445

Received multiple malfunction alerts. BSM & RCTW. Other safety features also inop. Dealership told me it was due to non-factory installed Cross Bars, faulty gasket allowed water into vehicle and flowed down onto the Engine Control Module. There was no way the amount of water said to have been in vehicle could have come from that 1 gasket, over 1" above roof. After $825+ and removal of cross bars water still leaking into car. Concerned issue will re-occur making safety features worthless, as well as damage side air-bags. These issues would all need to be corrected via out-of-pocket expense. Believe the issue is design flaw from Toyota.

NHTSA ODI 11520843

Roof rack design and grommet failure allows for water to flow into cabin headliner and down a-pillars and other areas where curtain airbag and other electrical components are housed. This can cause malfunction and/or failure of the vehicles crucial functions at any given moment. A class action lawsuit is filed on this. You need to step in and make it a recall and hold toyota responsible.

NHTSA ODI 11515982

Outside water (rain, carwash, etc) is leaking through the roof into the A-pillar and C-pillar areas and into the interior. Water is likely entering the air bag components in the front A-pillars on both sides, potentially causing a safety issue. Also concerned that water could be entering the electrical components in the dashboard. When researching the issue, found multiple complaints of this issue and also at least one class action lawsuit. Dealer is pushing back on covering this under the "Certified Pre-owned Comprehensive Warranty". https://www.carcomplaints.com/news/2023/toyota-rav4-roof-rail-leaks-class-action-lawsuit.shtml https://www.classaction.org/toyota-rav4-leaking-lawsuit https://www.motorbiscuit.com/lawsuit-alert-toyota-rav4-roof-leak-causes-water-damage-electronics-airbags/

NHTSA ODI 11515831

Driving home from work on 3/25/23 at 9:15 pm my dash lights starting going on and off flicking. “Power steering malfunction. Steering power low visit your dealer” “abs” also multiple dash lights came on at the same time. Brake light steering light. Got home and took video while parked to safely show the issue

NHTSA ODI 11513793

DCM unit failed. It controls Toyota safety connect and all communication to Toyota. If I were to be in an accident the SOS button to get help is inoperable. This has been reported to Toyota. This is a problem for nearly all the DCM units across the entire Toyota platform. Toyota is only willing to fix these defective DCM units under a 3 year 36k mile warranty. Considering the extent of the failure of these units across all their vehicles I believe Toyota should fix this systemic problem with their safety system outside their traditional warranty. Thanks

NHTSA ODI 11512233

A couple of months ago, I noticed water had somehow entered the inside of my car, collecting along the interior roof panel and inside the C-pillar close to the top of the driver door. I did a little research to see if I could figure out what the cause of it was. I found that many other owners of 2019 and 2020 Rav4's had similar problems. Their findings indicated that Toyota had equipped poor quality gaskets, along the the area in which the roof rail trim were fastened to the roof of the car. I also read that this problem could be fixed by the owner, but was unaware that the water leakage would come in contact with electrical components. Yesterday, I experienced first hand the result of this situation. When starting my car, the display board was indicating a multitude of warnings for system malfunctions. These included power steering malfunction, brake system malfunction, pre-collision warning malfunction, lane-monitoring, and on top of this the RPM gauge and engine temperature gauge were both malfunctioning. These warning/indicators persistently flashed and caused a loud beeping sound to go off. The warnings also informed me to not drive the car and see a dealer immediately. After taking it to the dealer, the technicians were able to confirm that water has leaked through the roof rail panels from the area I previously specified. They found water on fuse box/junction connectors. They also found corrosion on pins on driver front door connector, under dash harness connector and body harness connector. While the water damage did not lead to a car accident, it did cause serious concern for the potential risk of car malfunctions. This information will be soon be reviewed by my insurance provider.

NHTSA ODI 11511682