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

Coolant bypass valve leak. An known issue however dealership will not pay for repairs due to vehicle having 106000 mile. 6000 over what the bulletin 24TE04 states it will cover.

NHTSA ODI 11739682

Toyota made a defective coolant valve in their 2019-2021 cars that leaked spontaneously in these vehicles. Over 950,000 cars have been affected to date, including my 2020 Rav4. They are aware of the issue and made a customer support program for this issue which led to engines overheating/electrical code problems, which can cause a severe safety issue if left unrepaired. The program however has a limitation until November 2025 or 100,000 miles whichever comes first. When I was alerted of this, I brought my car to the dealer for service, but they wouldn't replace the part because it wasn't leaking too much at the time to need repair. However, just 4 months after the primary coverage expired, my engine code went off and when I brought my car, the coolant valve turned out to be defective and leaked into the electrical wire harness which then also had to be replaced in addition to the coolant valve. The repair cost was $1200 and both were required to keep the car driving safely and reliably on the road. Because my car had 120,000 miles and the known issue presented after Nov2025, Toyota refuses to cover the service, although it is a known manufacturing defect. Toyota is committing fraud to avoid covering this safety issue. The repair is expensive and if left unrepaired, the cars can spontaneously catch on fire on highways and in parks leading to wild fires and endanger others on the road. The toyota technician specifically informed me the issue was similar to other cars and known and the defect led to the destruction of the wire harness. To avoid a safety recall, Toyota reached a private settlement against class action lawsuit and created a limited CSP to avoid covering the defect in cars like mine to maintain their reliability status in consumer reports so cars like mine with little higher mileage won't be reported. It is fraud. I believe they are skipping on consumer repair bills that consumers on entitled to for their manufacturing defect.

NHTSA ODI 11739481

Sudden and complete failure of the water pump causing an explosion of the part. While traveling down the interstate, put lives in danger due to sudden jolt and rapid deceleration. Recently brought the vehicle in to correct recall on the engine coolant bypass valve. Issue with the bypass valve hastened the deterioration of the water pump to the point of failure. Told by mechanic that this is a known issue that just happens with Toyota’s. If this is a known issue, then it seems to me there should be another recall on the water pump. Plastic parts with highly corrosive liquids at high temps do not mix. Toyota needs to fix this costly issue.

NHTSA ODI 11727069

Engine light shows on in dash. Stopped to fuel up Car stalled, would not restart Diagnosed fuel pump No prior history of engine issue

NHTSA ODI 11692924

What component or system failed or malfunctioned, and is it available for inspection upon request? The flow shut-off valve (coolant leak) failed. This exact component was later included in Toyota’s official recall. The defective part was diagnosed by a mobile mechanic and replaced at a licensed independent auto repair shop. The failed component itself is no longer available, but all receipts and repair documentation are available upon request. How was your safety or the safety of others put at risk? The failure of the flow shut-off valve caused a coolant leak that created a significant safety hazard, as it affected the vehicle’s performance and drivability. This posed a risk to both my safety and the safety of others on the road, which is why I had the repair completed immediately before the recall was issued. Has the problem been reproduced or confirmed by a dealer or independent service center? Yes. The issue was first diagnosed by a mobile mechanic and then confirmed by a reputable independent auto repair shop, who identified the flow shut-off valve coolant leak as the root cause. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No inspection was conducted by Toyota, police, or insurance representatives. However, Toyota later issued a recall for this same component, confirming it as a known safety defect. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Yes. The vehicle experienced noticeable performance issues prior to the failure, which prompted me to call a mechanic. I did have multiple warning message and coolant leaking in addition to the performance issues of the vehicle. These symptoms appeared several months before Toyota’s recall notice for the flow shut-off valve coolant leak arrived.

NHTSA ODI 11690288

Bought the car with 114k on it now with 115k and I brought it in to Toyota because I have a “engine maintenance required” on the dash now they are trying to charge me almost $1000 because my car has over 100k miles on it and they said they won’t cover it.

NHTSA ODI 11687947

Shorted Coolant Bypass Valve, only 14500 miles on my 2020 Rav4, Class action Suit and dealerships want you to pay $800-$1000 to fix problem with a leaky defective plastic poorly designed valve that eventually leaks into the electrical connectors and shorts circuits the valve. There is no recall for this fix and Toyota won't honor the repair. This is a common issue and Toyota Turns a Blind Eye. Error Message: Engine Maintenace Required Call Toyota Dealership. I Did and they give me a song and Dance stating there is no recall for this issue. If i run the heater in the car the message for a few a minutes, then shut off vehicle maintenance warning will reset, once I turn on the AC it will come back on. So, I guess I have to keep the heater on all summer.

NHTSA ODI 11683443

Engine coolant bypass valve

NHTSA ODI 11676580

Engine maintenance message appeared on my dash. I took it to Big O's Tires and Service a car repair service provider. Upon connecting to the car and inspecting they told me it was a faulty possibly leaking engine coolant valve. The cost to repair is $916. This may cause the engine to overheat and possibly fail due to overheating. This can be very dangerous because it will happen if it does happen while driving which could cause an accident. I have not fixed the issue yet due to a lack of funds but will have to fix it as soon as a get paid because I drive my family in this car and cannot risk catastrophic engine failure. Please have Toyota recall this part as it is a very common failure amongst 2019-2023 Rav4s. A class action lawsuit is underway due to how often this issue arises. Thank you for your time.

NHTSA ODI 11676384

I was driving the car with no issues on [XXX]- made two 30-minute trips with no issues the same day. During a 15-minute drive, the car was fine until I was at an intersection 12 minutes into the drive [XXX] and [XXX] ). I was stopped at the intersection for maybe a minute, and when the traffic light turned green, I released my brake and went to accelerate when I got the following display message: "Engine Stopped Steering Power Low." The engine turned off, and I couldn't get the car to budge in drive or reverse. When I tried pressing on the gas pedal, it wouldn't budge and felt very stiff. I'm thankful this happened at a smaller intersection on a Sunday evening because my car wouldn't start back up and was stuck in the dead center of this intersection. Cars going East and South all had to drive around me. This put my safety at risk because I had to hop out of my car and redirect people around it until a kind passerby pulled over to help push my car to the right-side turning lane. I was standing in the middle of an intersection on a road with a 35-40 mph speed limit. After pushing the car to the curb and calling a few towing places (maybe 20 minutes later), I tried starting the car again, and it started with no issues whatsoever. I drove it the rest of the way back (for 3 minutes) with no problems, and I made another three 20-25 minute drives on it today. Nothing sounds wrong with the car; it's running with no issues. I would take my car to the dealership for a diagnostic, but I can't afford to right now. I will put my battery on a tender and use a multimeter to check the voltage within the next few days. Regular maintenance has been kept, and the car has never had this happen prior. I've never received the "Engine Stopped Steering Power Low" message prior to this incident. The car is available for inspection upon request. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11673543

Coolant Bypass Valve failure at 40k miles - 2020 rav4. Replacement at dealership is costing over 800$.

NHTSA ODI 11671670

The coolant bypass valuve has failed. There looks to be a class action lawsuit currently underway.

NHTSA ODI 11667296

My vehicle Toyota RAV4 Hybrid 2020 began lost power and jerk on highway driving and then following messages appeared: Hybrid System Malfunction, A malfunction in electronic control of engine, throttle or automatic transmission has been detected and check engine light. This happened in September 2024. Toyota dealership replaced the low fuel pressure sensor A after my complaint and vehicle diagnostic, but it did not help. I recently had the same problem while driving on the highway for a long distance.

NHTSA ODI 11665668

Coolant Bypass Valve, vehicle is available for inspection. Confirmed by Certified Toyota Dealership. There is a know defect with the Coolant Bypass Valve in 2019-2023 Toyota Rav4. Maintenance Required Light Only Comes on when the Heat is switched to Air Conditioner.

NHTSA ODI 11662507

I have a 20202 Rav4 Hybrid and the engine short block has malfunctioned due to no error on my part, in my research there was a recall for this EXACTLY this issues in other cars of this year/make/model - although my vehicle initially did not qualify for this I believe that this in fact related and that Toyota should be responsible for the repair or replacement of the engine. The car is currently with a Toyota Dealership Service Center, Lake City Toyota in Seattle, WA but they have not been helpful. They have given me vague answers and have sent the engine offsite to a machine shop and keep requesting that I pour additional money into fixing an engine that clearly had a manufacturer defect. My car has always been serviced at Toyota dealerships, as suggested by Toyota. My car has never had previous issues until the engine light came on one day, i checked the coolant and it was empty - first replaced the fluid, let it sit overnight, then drove it around the block to circulate the coolant - when the reservoir emptied again I immediately made an appointment to take it in. The Dealership has not given me any paper invoices or written confirmation/notice of what is happening aside form continuing to ask me to pay more money to fix an engine that is clearly related to the national recall issued.

NHTSA ODI 11662539

"Engine maintenance required. Visit your dealer" prompt after turning on Air conditioning. Message of Engine coolant bypass valve circuit short to battery or open upon diagnostic test

NHTSA ODI 11657851

Coolant relief valve failure

NHTSA ODI 11657457

My Rav4 xle 2020. Starting the engine up it shakes and blows white smokes for 5 seconds and smooths out. This symptoms happens every time when engine is turn on I have to fill coolant once a week.

NHTSA ODI 11657653

The coolant valve is malfunctioning and causing an engine safety light to be on constantly

NHTSA ODI 11655103

Coolant bypass valve failure

NHTSA ODI 11653965

The wiring harness to the lithium battery is corroded, and it is unregulated. My repair shop said the car is unsafe to drive because of the amount of unregulated electricity in the battery. Also, the cruise control doesn't work. My repair shop says this is happening to other vehicles. Parts and labor total almost $7,000.

NHTSA ODI 11653453

Warning light: Engine Maintenance Required Coolant Bypass Valve

NHTSA ODI 11652385

Continuous Warning light display : Engine Maintenance Required Visit Your Dealer. The OBD diagnostic scanner lists the faulty system as follows: Code P268115. Engine coolant bypass valve circuit short to battery or open circuit. This appears to be a common fault on certain Toyota RAV4 years.

NHTSA ODI 11649709

The coolant bypass valve has been failed prematurely therefor engine heat up and there is a warning on my dashboard that say "engine maintenance required"

NHTSA ODI 11647790

at only 55k miles my 2020 toyota rav4 has shown an “engine maintenance required” sign. not to be mistaken with general maintenance. apparently this is a widely common issue where brand new toyotas are having cooling bypass valve issue. however concerningly so, because there are no recalls for this problem yet seemingly every rav4 has this problem? how is there no recall, everyone is paying out of pocket for essentially poor manufacturing, its outrageous, also considering the part itself is under $100 but some dealers are charging anywhere to $600-$1300. it’s predatory and outright wrong.

NHTSA ODI 11647901