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

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

1. I had to have Injector Fuel Service due to my vehicle having a sluggish feeling while driving from Stop to Start. The vehicle also had a throttling motion while driving. 2. A message appeared on dashboard after a recent visit to the dealership after normal maintenance service, “Engine Maintenance Required” “Reach out to Dealer.” This message specifically shows while I start up my vehicle and will not disappear if cancelled. “This is a warning for a coolant bypass valve failure”

NHTSA ODI 11590766

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

Vehicle was taken in for a oil change. At check-in I was told that I would be given a rental vehicle due to the overhead rails recall, leaking inside the vehicles at that time I advised of a gas smell which I have been smelling for several years and it was getting stronger. I was told that there was something wrong with the fuel pump and it would need to be replaced and they would also be replacing rails from the top of my vehicle because there was water leaks inside my car, I advised that water has been leaking in my car for several years and clips were already placedbout two years ago. Several days later I received a phone call that my vehicle was ready to pick up when I got there i was informed that the fuel pump assembly was replaced and intake. Manifest gasket , throttle gasket , fuel pump gasket replaced EGR valve replaced EGR inlet gasket replaced EGR valve. ad gasket replaced EGR cooler gasket replaced. I was also told that my air filters would need to be changed and I did consent to my air filters, the air element and a brake system flush as recommended after picking up my vehicle which had 34033 miles on it on 1/24/24. On 2/10 I was driving and a warning flashed on my car and spoke to me it said that there was a malfunction detected in the engine, transmission or throttle of the vehicle and I need to contact Toyota. I was two miles away and drove directly to them. They took the vehicle for several hours. I was told it was the alternator because my lights have been going dim and very bright. I advised that I have issues with the windows closing since the most recent repair as well and the vehicle is losing power. After almost 4 hours I was informed it a thermostat. Everyone had gone home and they could not give me a give me a rental so I had to drive this vehicle until Monday afternoon. The thermostat and gasket were replaced and I was charged because they used insurance without telling me. I believe this is a malfunction in their system related to origina

NHTSA ODI 11571919

-Inspection found coolant bypass valve seized recommendation, was to replace coolant hose with bypass valve. YES, the car is available for inspection upon any request -Safety risk unknown if not fixed -Michaels Toyota of Bellevue Washington confirmed on September 23rd 2023. I brought the car in originally on September 9th 2023 for a 10,000 mileage service and oil change. when I called to ask why the engine maintenance notice wouldn't turn off. I was scheduled to bring the car back on September 23, 2023 the needed part was not in stock nor covered by the factory or powertrain warranty with 31,2002 miles on it. The warning light came on at the same time the service and oil change was due. I was stopped a month prior by a random mechanic who noticed the car was leaking abnormal amounts of what he said could be coolant on the passengers front undercarriage. This leaking has been happening for approximately a year and I was not notified the previous 3 times the car had been in for inspections.

NHTSA ODI 11549804

Fuel tank fill up only 9-10gal wherein published rating to 14gal tank. There should be a recall on changing fuel pump but my VIN does not show any recall

NHTSA ODI 11539826

Car shut off while driving and once restarted check engine light came on. Safety was at risk because I was driving with cars behind me. After check trouble code it was determined faulty gas pump.

NHTSA ODI 11533528

Cannot fill the 14.5 gallon fuel tank at the pump. Half tank takes 5.2 gallons and empty tank takes 10.2 gallons when empty light comes on. Distance to empty only reads 380 mpg on a full tank of fuel and vehicle advertised to go 580 miles at 40 mpg. This situation causes range anxiety and constant stopping at the fuel pumpto only add 5 gallons at a time not knowing how much available fuel at any point in time. I do achieve 40 to 43 mpg on average. Maybe 39 on highway as I stick close to the speed limit. Dealers state nothing wrong and will not help. Toyota corporate states vehicle working as it should. This is not correct. Please help.

NHTSA ODI 11519628

The front suspension has problem I noticed recently the sway bar and front studs of the car is not reliable and also the fuel tank also has issue even if the tank is not fuel it refuses to take more fuel

NHTSA ODI 11517936

Toyota and Lexus vehicles equipped with fuel pumps and manufactured by dense international America and its affiliates contain a defective component. - settlement paper states this that I received in the mail, in which I am a class member of. I was driving my car roughly a year ago, when my car shut off in the middle of the road and would not turn back on period. Road side assistance had to come retrieve my car, and haul it to the dealership. Today I still have this faulty fuel pump in my car, that could shut off at any point in time while I'm driving down the road.

NHTSA ODI 11492310

Before purchasing this car (used, certified) I asked the salesman if the 2020 RAV4 Hybrid had the fuel filling issue I had read about in the 2019. He said he'd never heard of it; I told him it was all over the internet and he said "oh, that's for earlier models." So I bought the car. Immediately had issue where I can't get more than 10.5 gallons of gas in the tank when fuel light is on and DTE is 20 or less. The advertised fuel capacity is 14.5. I have a long daily commute and bought this car for the range. I asked the dealer again and they provided me with Toyota's chart that shows 2.5 gallons of "reserve" at the bottom and another 1-2 for "air" at the top of the tank. Yes, Toyota thinks you can fuel their cars with air. I then called Toyota HQ and they said the fuel tank on this car was already taken care of as part of their customer support bulletin. They said it was still under warrantee and should be replaced again — "fixed properly." Dealer still refuses to take care of this issue, telling me now that the 2.5 gallons of "reserve" on the bottom is "unusable." As a woman who commutes long distances daily on rural roads, this frightens me. What if I run out of fuel because I think that I've got 2.5 gallons of "reserve" to make it to the next open gas station — only to run out of gas on a cold, dark winter's night? As dramatic as I am being, the point is that not only is this is a potential safety issue, it's also absolute fraud on Toyotas part — a car advertised as having a 14.5 gallon/572 mile range takes only 10.4 gallons with a 425 mile range.

NHTSA ODI 11490521

We are not able to fill the gas tanks up on our vehicles to full published capacity of 14g. Lucky to get 10g. This limits the vehicle’s driving range.

NHTSA ODI 11480200

Toyota emphatically advertises that its 2020 RAV4 hybrids come equipped with a 14.5-gallon gas tank that can hit a 580-mile driving range. The cars suffer from the apparent fuel tank issue that harms both the environment and the benefit of the cars’ electric power. The RAV4 hybrids not only fail to comply with federal and state gas tank regulations, which prohibit the sale of vehicles that cannot fill 90 percent or within two gallons of their nominal gas tank capacity, but suffer from substantially reduced driving range. The fuel tank defect poses an environmental and safety hazard in that drivers are left to guess how much gas they have left and effectively encouraged to top off their fuel tanks in order to fill up as much as possible,

NHTSA ODI 11446615

My car’s distance to empty never goes above 420 miles, despite a visit to the Lexington MA Toyota dealership with this complaint. Published range is about 580 miles. The dealership reset values in the car, but this did not make any difference, and at no point during my ownership of the car (which was bought new) has the range on the dashboard when the tank is full exceeded 430 miles.

NHTSA ODI 11429669

FUEL GAUGE NOT PROPERTY WORKING AND GIVING INADEQUATE FUEL AMOUNTS LEFT IN TANK. AT 1/2 OF TANK IT'S MISREPRESENTATION OF ACTUAL FUEL LEFT THAT CAN LEAD TO BEING STRANDED.

NHTSA ODI 11406231

TOYOTA IS SELLING RAV4 HYBRID 2020 WITH DEFECTIVE GAS TANK. THEY ADVERTISE A 14 GALLON TANK AND ONLY 9-10 GALLONS FILL IT. TOYOTA KNOWS ABOUT THE PROBLEM AND THEY ARE STILL SELLING VEHICLES TO THE PUBLIC.

NHTSA ODI 11403990

FUEL TANK CAPACITY WHEN THE CAR WAS BOUGHT NEW WAS 9.3 GALLONS BETWEEN LOW FUEL LIGHT TO REFUEL CLICK AT GAS PUMP. AFTER FUEL TANK CAPACITY AFTER FUEL TANK AND PUMP REPLACEMENT IS 11.3 GALLONS. THIS IS BETWEEN WHEN THE LOW FUEL INDICATION ASSERTS TO WHEN REFUELING CLICKS AT THE GAS STATION. THIS IS STILL WELL BELOW THE ADVERTISED FUEL CAPACITY OF 14.5 GALLONS. A SOFTWARE RESET WAS DONE, BUT THE FUEL CAPACITY DID NOT CHANGE. THIS CAUSES US TO REFUEL MORE OFTEN THAN EXPECTED SINCE THE ADVERTISED RANGE OF 500 MILES ON A TANK OF GAS CAN NOT BE ACHIEVED. HAD WE KNOWN OF THIS ISSUE WHEN WE BOUGHT THE CAR, WE WOULD EITHER NOT HAVE BOUGHT THE CAR OR PAID LESS. TOYOTA IS STILL SELLING THESE CARS WITHOUT WARNING CUSTOMERS OF THE FALSE ADVERTISEMENT.

NHTSA ODI 11402874

THE MILEAGE I AM GETTING IS FAR BELOW THE STATED RATING ON THE STICKER. I AM AVERAGING ABOUT 33.5 MPG IN MIXED DRIVING WHEREAS THE STATED RATING IS 41 MPG OVERALL. IT'S NOT EVEN CLOSE. THE TANK WAS RECENTLY REPLACED BECAUSE YOU COULD NOT FILL THE TANK. EXTREMELY DISAPPOINTED IN THE MILEAGE WHICH WAS THE MAIN PURPOSE OF BUYING THIS VEHICLE. SOMETHING NEEDS TO BE DONE.

NHTSA ODI 11397822

ON FEBRUARY 6, 2021 IN ATLANTA GA, THE VEHICLE, WHILE IN MOTION AT AROUND 30MPH, DISPLAYED A 'HYBRID SYSTEM MALFUNCTION' WARNING AND BEGAN BEEPING AND TREMBLING. THE WARNING SAID THAT THE CAR MUST BE STOPPED WITHIN 0.9 MILES BUT LASTED FAR LESS THAN THAT, FULLY LOSING ANY EFFECT OF THE ACCELERATOR PEDAL MID-TRAFFIC. THE VEHICLE COASTED INTO A PARKING LOT ON MOMENTUM AND WAS STOPPED WITH A FINAL WARNING THAT BRAKING POWER WAS REDUCED. HAD THIS VERY SITUATION OCCURRED ON AN INTERSTATE, IT EASILY COULD HAVE BEEN FATAL TO MY WIFE, WHO WAS DRIVING AT THE TIME, AND TO OUR UNBORN CHILD. THE VEHICLE IS 9 MONTHS OLD, WAS PURCHASED NEW, AND HAS AROUND 15,000 MILES.

NHTSA ODI 11395034

TOYOTA STATES THE RAV4 HYBRID HAS A 14.5 GAL GAS TANK. WHEN GAS GAUGE SHOWED 27 MI LEFT, I WAS ONLY ABLE TO PUT 11.8 GAL IN TANK. DEALER TOLD ME TO JUST ASSUME I HAD MORE GAS LEFT. THIS WAS AFTER THEY HAD REPAIRED THE RECALL ON THE TANK APPROVED BY TOYOTA. NO WAY TO KNOW HOW FAR I COULD GO. THE RECALL DIDN'T WORK

NHTSA ODI 11387892

FUEL-TANK CAPACITY IS LISTED AT 14.5 GALLONS THE TANK WON'T ACCEPT MORE THAN 9 OR 10 GALLONS.

NHTSA ODI 11387321

VEHICLE GAS TANK WILL NOT FILL TO CAPACITY.. I AM STOPING AT GAS STATIONS ALL THE TIME BECAUSE I AM FLYING THROUGH GAS ..AND IT'S A HYBRID ..WON'T FILL MORE THAN 9 OR 10 GALS .. THE VEHICLE HAS NO RANGE FOR A HYBRID WHICH IS THE EXACT OPPOSITE OF WHAT THEY SAY WHEN THEY'RE TRYING TO SELL YOU ONE.. HAD I KNOWN I WOULD BE AT A GAS STATION EVERY 3 DAY'S WITH A HYBRID I WOULD HAVE NEVER BOUGHT IT

NHTSA ODI 11385044

WHEN I FILL MY GAS TANK, IT DOES NOT SHOW FULL. I BOUGHT THIS SUV 4/17/2020. ALSO, BURNS THROUGH GAS QUICKLY. I SEEM TO GO GET GAS OFTEN AS IT QUICKLY BURNS THROUGH HALF A TANK, THEN STAYS THERE FOR A WHILE THEN QUICKLY DOWN TO 1/4 TANK. I WAS SENT FROM TOYOTA THAT THEY KNEW THIS IS A PROBLEM BUT DON'T KNOW HOW TO FIX. NOW WHEN I CALL THEM, THEY TELL ME THEY KNOW NOTHING ABOUT THIS PROBLEM. YET IN THEIR LETTER SAID DO NOT TOP OFF AND DO NOT WAIT UNTIL THE FUEL LIGHT OR WILL RUN OUT OF GAS.

NHTSA ODI 11383042

THE 14.5-GALLON GAS TANK IN MY 2020 TOYOTA RAV4 HYBRID HAS A DEFECT THAT PREVENTS THE TANK FROM BEING FILLED TO CAPACITY. THIS DEFECT NOT ONLY FAILS TO COMPLY WITH FEDERAL AND STATE GAS TANK REGULATIONS, WHICH PROHIBIT THE SALE OF VEHICLES THAT CANNOT FILL 90 PERCENT OR WITHIN TWO GALLONS OF THEIR NOMINAL GAS TANK CAPACITY, BUT SUFFER FROM A SUBSTANTIALLY REDUCED DRIVING RANGE. THE FUEL TANK DEFECT PREVENTS ME FROM GETTING ANYWHERE NEAR THE VEHICLES' ADVERTISED 550-PLUS-MILE RANGE (I AVERAGE 400-425 GALLONS A TANK), WHICH WAS A MAJOR SELLING POINT AND FOR WHICH I PAID A PREMIUM PRICE FOR; THIS HAPPENS AT EVERY INTERVAL I HAVE TO FILL UP ON GAS. I FEEL THIS IS A SAFETY HAZARD AS WELL, I MAY RUN OUT OF FUEL WHICH MAY RESULT IN AN ACCIDENT OR LEAVE ME STRANDED ON THE SIDE OF A BUSY OR DESERTED ROAD AND WITH A NY WINTER, IT IS JUST NOT SAFE TO BE STRANDED IN THE COUNTRYSIDE WHEN IT IS FREEZING COLD OUTSIDE. RUNNING OUT OF FUEL MAY ALSO DAMAGE MY VEHICLES FUEL SYSTEM TOO! THE OWNER'S MANUAL WARNS THAT IF MY VEHICLE RUNS OUT OF FUEL OR THE FUEL IS TOO LOW, THE HYBRID SYSTEM MAY NOT BE ABLE TO START.

NHTSA ODI 11378093

THE FUEL TANK IS RATED AT 14.6 GAL BUT THE MOST I HAVE BEEN ABLE TO GET OUT IS 11 GAL. THE ISSUE IS CONSISTENT ACROSS EVERY FUELING PERIODS AND AFTER TAKING IT TO THE SERVICE CENTER TWICE, THE ISSUE HAS NOT BEEN FIXED AND THE RESPONSE HAS BEEN THAT THE FUEL TANK HAS NO ISSUES. I HAVE SHOWN THE PROOFS TO THE SERVICE CENTER AND YET THEY DENY CLAIMS.

NHTSA ODI 11377489