What 625 owners told NHTSA about the 2020 Toyota RAV4 Plug-in Hybrid

my 2020 RAV4 (48,000 miles), when I start the engine and turn on the A/C, the warning light comes on:Engine maintenance required.

NHTSA ODI 11601879

Coolant bypass valve needs to be replaced. Car under 60k miles and should be covered on the powertrain warranty but is being required to be repaired out of pocket otherwise will ruin engine

NHTSA ODI 11601326

Coolant bypass failed at 55,000 miles. This car has barely been used. This car is almost in mint condition and the coolant bypass has failed resulting the car not being able to be driven at all until fixed. The dealer is charging over $600 to repair. This is an ongoing issue with hundreds of Toyota RAV4 owners.

NHTSA ODI 11600961

I currently own a 2020 Toyota Rav 4. About two weeks ago I got a notification on my car saying "Engine Maintenance Required" i had taken my car to Toyota wondering what the problem was. They informed me it it the coolant bypass valve without hesitation. This is going to cost me more money than I want to spend. To make the situation better the parts needed are on back order for almost two weeks. The fact this is a common problem right now and there is no Recall is unacceptable. You are causing thousands of customers to spend an unnecessary amount of money and wait weeks just to get the correct parts to fix the situation. There is currently a lawsuit against Toyota because of this issue. There needs to be a recall immediately.

NHTSA ODI 11600071

my car has barely 40,000 miles on it when I received an "engine maintenance required" sign. When I went to the dealership, they said its the coolant bypass. I went on reddit and many 2020 rav4 Toyotas are having the same issue. This should be recalled as the repair is too expensive - above $800.

NHTSA ODI 11595780

Trunk lift gate unable to close or open properly due to faulty lift gate shock and strut supports as diagnosed by dealership in January 2024. As of then there is was no ETA on parts to complete repair and was blamed on Toyota not supplying enough parts beyond new vehicles and warranties vehicles. Only resolution was to not use the trunk, or as little as possible and told that I was added to a 700+ person waiting list.

NHTSA ODI 11593290

on 5/28/24 the vehicle air bag lights and front passenger seat light was flashing and an alarm continuously went off with a message to visit a dealer for service. On 5/29/24 the vehicle was brought in for inspection to a Toyota dealer. I was told an electrical wiring needed to be replaced. Dealership did that but it did not correct the issue. Codes were not resetting. They are now saying it is a wiring/electrical issue under passenger seat and saying they have been communicating with Toyota. We do not have a Toyota extended warranty but vehicle has 32K miles and are told by dealership Toyota should be covering. I am submitting this to have this on record as we have warning lights, messages, etc. occurring which is a safety issue under NHTSA. Dealership keeps increasing charges for parts and labor and states our 3rd party warranty may or may not cover charges. They are trying to determine the issue and if Toyota will cover and resolve.

NHTSA ODI 11592133

The contact owns a 2020 Toyota Rav4. The contact stated while driving approximately 35 MPH, the "Engine Maintenance Required" warning illuminated. The contact stated that the instrument cluster displayed the warning; however, all information, including the speedometer, mileage, fuel, and temperature gauge went blank. The contact stated that power was not lost and was able to continue driving to the destination. The contact stated that when the vehicle was turned off and restarted, the instrument cluster functioned as needed. The contact stated that the failure was intermittent at first but had become a recurring failure and occurred at various speeds. The contact had taken the vehicle to a local dealer; however, the vehicle was not yet diagnosed or repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 48,000.

NHTSA ODI 11589158

Coolant bypass valve

NHTSA ODI 11586887

Coolant bypass value failure 1000$ to replace on a vehicle that’s only a few years old Toyota refuses to fix it

NHTSA ODI 11585966

My name is [XXX] and I would like to file a complaint against Toyota. I purchased my RAV4 XLE in 2020 after returning home from military training. This was my dream car and I was filled with joy to be able to purchase it. In the four years I have had it, I have had minimal issues, nothing to note other than normal wear and tear, until recently. The "Engine Maintenance Required" light came on roughly 3 weeks ago. I deemed it to be my oil change notification and reset it knowing when my next oil change was due. The notification came back on to which I started investigating further. I typed in "2020 RAV4 Engine Maintenance Required" into Google and was surprised at how many car forums and complaints popped up for this exact problem. It was an astronomical number of complaints made by loyal Toyota owners. I scrolled for an hour reading everyone's story, which was almost identical to mine. I made an appointment at my nearest Toyota in Bountiful, UT to get a diagnostic test done. Not to my surprise, the code that was tripping the system was for the 'coolant bypass valve.' I was quoted $660 for the parts and labor. After getting a price breakdown and verbally stating how frustrated I was with this issue due to how many others online had the same issue and there not being a recall, I felt like my only option was to pay it and suppress my anger. I am not upset with the Toyota dealership I went to. I am upset that this is a very known issue that even the mechanic verbally stated knowing about, and that Toyota as a large corporation is not doing right by the people who swear by owning Toyota's and their reputable reputation. I called two private mechanics about the issue and they both stated that they have worked on several RAV4's with this issue. It is not cosmetic, it is a critical issue that needs to be fixed. I hope this complaint makes it to the right hands and a solution is implemented so people can enjoy their car without these worries. Thank you. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11584960

A week prior to this incident, the 2020 RAV4 was taken to Toyota for its maintenance check where everything was checked, replaced and changed. However, the last two days an incessant message keeps popping up on the dash stating “engine maintenance required… Visit your dealer” taking up the entirety of the middle screen inhibiting my ability from seeing my speed, mileage, distance to empty , time, lane assist and other car information that I normally rely on. I have pressed the “arrow back” or “back” button numerous times but three seconds later the message pops again inhibiting me from being able to use necessary car controls to stay safe. The engine on the 2020 RAV4 needs to be recalled as my car only has 55,000 miles on it. I have talked to numerous professionals within the motor industry in which they state these engines have lower stability and life expectancy than PREVIOUS engines used in older RAV4 models. Not only the engine, but the messaging system within the RAV4 needs to be fixed immediately as the communication of maintenance WHILE driving is a hazard. If I cannot look at texts to even just simply read it, why is there is message bright and in the middle of my dashboard popping every 3 seconds with a bright red triangle stating that I need “engine maintenance required,visit a dealer”. This is a safety issue and one in which almost nearly cost me my life.

NHTSA ODI 11579309

This is a known issue. Coolant Bypass Valve Issue Error on value says "Engine Maintenance Required, Visit Your Dealer." We have been waiting on the recall at 27,000 miles (brand new purchased). We are at 50,000 miles now and still no resolution and the error stays.

NHTSA ODI 11577294

* Coolant Bypass Valve * This problem costs $800 to fix at the Toyota Dealership. *My car is a 2020 Rav4 with only 32k miles on it. * After reading thousands of complaints on websites from other 2020 Rav4 owners with the exact same problem, I think there should be a recall as this can be a dangerous issue if the engine overheats. I am shocked that nothing has been done about this yet. *The only warning was a routine maintence light that comes on every 5,000 miles.

NHTSA ODI 11572428

The following is an issue involving my 2020 RAV4 Toyota battery manufacturing defects that ended the life of my RAV4 battery. The mentioned event occurred on [XXX], and a report was created and recorded by a Toyota representative on [XXX], via (800) 331-4331 phone call, with the reference report number [XXX]. The nature of the issue was that my 2020 RAV4 battery parts came loose from the inside, and the metals were rubbing with each other, causing the smoke and the battery to overheat, ending its life due to the mentioned manufacturing defects. Based on the dangerous, alarming issue of overheating and dense heavy smoke from the battery, I left it at the dealer for service to prevent any toxic fumes, fire, or explosion. I told the dealer adviser that those manufacturing defects are a serious safety concern that should be reported in the public’s best interest to avoid any possible tragedies. I noticed when I picked up my car from the dealer that the battery manufacture defect was not recorded in the paperwork I had received; the manager and the advisor didn’t show any sense of urgency to the matter, so I filed a report to Toyota Motor North America Headquarters, Plano Texas. Report number: [XXX] The dashboard panel never displayed any safety hazard warnings or any symbols indicating the conditions of the smoke and battery overheating were jeopardizing my life and my family aboard while I drove with them. I paid $ 552.55 for the battery and a diagnostic service; management did not want to acknowledge that a manufacturing defect ended the battery life. Customers should not be responsible for replacement costs when the event is caused by manufacturing imperfection “even though the warranty is over.” The dealer advisor and management know that these manufacturing battery defects happen. Still, nobody ever informed me to be mindful of the dangerous state of faulty battery defects when I purchased my 2020 RAV4. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11571345

Car operating as normal in the morning, few hours later went to start up car again and had message saying “hybrid system malfunction”. Drove it around for a few minutes then other lights started flashing, lane departure, traction control, crash detection. They all went away and except the hybrid malfunction warning.

NHTSA ODI 11565734

Engine bypass valve sensor is faulty. Many users have reported this past 40k miles on RAV4 2019-2021

NHTSA ODI 11558462

2020 RAV4 hybrid. Vehicle doesn't start; requires a jump, which is inconvenient or unsafe, depending on where it happens. Intermittent occurrence, ~ 3 times/year. Toyota checked 12V battery, pronounced OK, of course the car was driven to the shop for the check, so was operating at the time. I've checked the battery when the car wouldn't start and found it to be a little low (11.5V) but by no means fully discharged. Not associated with leaving components on (we are careful to turn everything off) or weather; the vehicle is garaged in the winter. I turned off the "Bluetooth" system which we never used and haven't had this issue over the past year. Suspect that the "Bluetooth" system was operating even when the vehicle was off?

NHTSA ODI 11558087

Got an engine maintenance required alert, took to Toyota and they advised the coolant bypass valve needs to be replaced at just 38,000 miles. Googled this and found out many 2020 RAV4 with the same issue at just under 40,000 miles. Also a common issue is the voltage being low and we already had to get the battery replaced once and still get alerts of it being low after replacement. Have to pay today $765 for the coolant bypass to be replaced, will have the receipt later in the day.

NHTSA ODI 11549407

2020 Toyota RAV4 XLE purchased July of 2020. Just hit 35K miles and an "engine maintenance required" message appeared. The error message would not go away while driving and blocked the entire display screen. There is an issue with the Engine Coolant Bypass Valve that costs $700-$1000 to repair. The part and repairs are not covered by the 60,000 power terrain warranty.

NHTSA ODI 11546681

I have a 2020 RAV4 Toyota with 60,000 miles.. I have replaced the car battery 3 times now Toyota has no clue why. The 2nd battery only lasted 8 months and it was a name brand battery (Die Hard).. The engine problem started with a warning light that i could not turn off.. I took my car to Toyota and they told me right off (without checking) it was because of a Coolant Bypass Value, the Toyota service lady said it was her 5th Rav4 this week with the same problem. I checked on line and was surprised how many Rav4 customers were complaining about the same issue so i reported it to you.. Toyota is charging me $900 to replace.

NHTSA ODI 11545907

Despite the upkeep of maintenance the light warning light won’t go off. I follow rav4 groups this is a common problem.

NHTSA ODI 11544229

Coolant bypass valve failure my car has less than 50k Dealerships informed me that they fix around 10 a month for that part there is a defect regarding this pump

NHTSA ODI 11544348

On or about 8/21/23, we were driving from Vermont back to our home in New Jersey when the sound system started malfunctioning. First, we lost all sound (safety warnings, as well as radio). The sound returned and then cut out again repeatedly. Then, the speakers emitted loud (full volume) static and popping sounds despite the audio system being "off." At the time, we were driving at approximately 65 mph on a highway with our two young children. The noise was so loud that it was difficult to focus on driving. The static and popping sounds continued until we pulled over and shut the car off. These failures have continued and increased in frequency since that time. Our safety was put at risk in two ways: 1) all of the safety warnings were and are muted and ineffective and 2) a full-volume static/popping sound while driving at highway speeds could have caused an accident. Subsequently, we did the following: -Googled the issue and found a relevant Technical Service Bulletin published by Toyota in September 2020 that applies to our make/model and VIN. It is labeled T-SB-0086-20 and can be found here: [XXX] . This suggests the issue applies to multiple Toyotas. The Bulletin indicates the VIN number where the issued stopped -- suggesting Toyota took steps to fix it. There has been no recall related to this issue and we were never notified of this issue. The issue is apparently related to a defective amplifier. -Brought our vehicle to our local Toyota service center (Paul Miller Toyota of West Caldwell NJ). An employee there was able to reproduce and confirm the issue and recommended replacing the amplifier. -Called Toyota to report the problem and register a complaint given the safety issues, failure to notify us of the problem even though it was known to Toyota, and the cost of repair ($2640). There were no warnings, messages, or other symptoms of the problem prior to the failure on or about 8/21/23. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11542654

Power steering light is on and possibly due to water penetration from recent heavy rainfall.

NHTSA ODI 11542414