What 375 owners told NHTSA about the 2021 Toyota RAV4 Plug-in Hybrid

“Required Engine Maintenance- Visit Your Dealer” message came on the dash. After doing some research and troubleshooting; it appeared to be the coolant bypass valve that everyone has had issues with. The problem was then confirmed with a local provider who instructed us to contact the dealer to see if they’d cover the repair. Otherwise the repair by them would be $700. Toyota customer service told us that there is no TSB or Recall for this issue. We would need to have the issue diagnosed and then pay out of pocket for the repair. This is an issue that spreads throughout so many vehicles that it needs to be a recall.

NHTSA ODI 11736285

Upon taking my 2021 Rav4 Hybrid in for the rear traction motor cable corrosion recall (25TD01) on 5/7/2026, I was told there are no parts, no estimated arrival time, and therefore not even a rough estimate for a timeframe of repair. I was told that no one would inspect or evaluate the part in question to indicate if the car was safe to drive. I expressed my extreme concern given the recall includes risk of power failure, even while driving. I received inconsistent, avoidant answers and an absolute denial to remedy the situation in any way. I was told the dealership is "Dolan" and not "Toyota". I again expressed my concerns about safety and the dealerships' denial to, at minimum inspect the recalled part and/or housing of the part. Emily, the Service manager stated that Toyota does not "allow" loaner vehicles for this particular recall. She could not provide any sources for this information. To summarize; the dealer with not provide an inspection of the recalled part and/or housing, or give an estimated timeline for repair given I am #125 on a waitlist. There is a complete lack of regard for mine or my children's safety as the dealer will not provide any assessment of how bad the damage could be. They suggested that I continue to drive the vehicle, acknowledging all of the safety hazards that could occur. I am terrified of the possibility of having an accident with my kids in the car due to this recalled part failing, not having a vehicle to get to and from work, and the potential additional costs that this unaddressed recall issue could cause. Please advise!

NHTSA ODI 11736428

The coolant bypass valve failed and the car is a 2021 Rav 4 LE. I called Toyota and according to the VIN it is not covered for this type of repair. I see quite a few cars have had this same issue, all Toyota's. It was inspected and repaired at a local Toyota Dealership but I had to pay out of pocket for the repair. There was a brief warning light that said "Engine Maintenance Required" See dealership or some such thing. Of course it's a safety issue if the coolant valve bypass failure causes the car to overheat.

NHTSA ODI 11734654

While driving at highway speeds (approx. 65 MPH), the vehicle suffered a sudden and catastrophic loss of motive power. The "Hybrid System Malfunction" warning illuminated, followed immediately by a "Check Engine" light. The vehicle entered a fail-safe mode, then completely shut down. The steering wheel locked, making it extremely difficult to maneuver the vehicle to the shoulder in a dark, remote area with freezing temperatures. This presented an immediate life-safety risk to all occupants. Following the incident, the vehicle was presented to two separate authorized Toyota dealerships in the US for emergency assistance. Both failed to provide the standard of care required for a high-voltage safety failure. The first dealer refused to perform even a basic safety inspection or intake the vehicle, stating they had no hybrid technicians on weekends. They turned the vehicle away without safety warnings, forcing the operation of a chemically failing vehicle on public roads. The second dealer attempted to charge a diagnostic fee. However, when questioned, they admitted they also did not have a hybrid-certified technician on site. They attempted to bill for a diagnostic service they knowingly could not perform. This fraudulent charge was only rescinded after it was challenged. They subsequently refused further assistance, leaving the occupants stranded. The vehicle was eventually towed to a third dealer (in Canada) where it was diagnosed with severe corrosion of the High-Voltage Floor Under Wire Harness (MGR Cable), a known defect. The dealer confirmed the rear motor cable was corroded and required replacement. The repair involved replacing the cable and installing a "splash guard" cap. No prior warning signs occurred before the sudden highway shutdown. This failure is a result of the manufacturer's failure to adequately seal high-voltage components against corrosion and the dealer network's gross negligence in refusing emergency safety support.

NHTSA ODI 11703844

The contact owns a 2021 Toyota Rav4. The contact stated that while her daughter was dropping her off, the daughter shifted to park(P), and the vehicle made an abnormal static sound. The contact stated that the failure recurred upon shifting to drive(D). There was no warning light illuminated. Additionally, the contact stated that there was an abnormal sound coming from the engine. An independent auto electrician was contacted and informed the contact that the abnormal sounds could be related to an engine failure; however, the vehicle was not diagnosed or repaired. The vehicle was taken to the dealer, where the contact was informed that no failure was found. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 67,314.

NHTSA ODI 11699009

I have a carbon monoxide leak going on since I bought this vehicle. I have been complaining about noises I have been hearing from the drive train and got a diagnosis from the same dealer with well over 1k worth of work. This has caused me a lot of lost money since I have been from dr to dr and back and forth with the dealership and now I tested for carbon monoxide and it’s leaking into my vehicle the dealer keeps telling me it’s fine it need a tune up or evap system clean. I am not able to drive this car safely and I have permanent brain damages from the carbon monoxide gas

NHTSA ODI 11688113

The vehicle has never been in an accident and has been garage kept. There were 5 pinholes in the radiator that were slowly dripping over time. My radiator fluid went so low my car overheated and had to be taken in for repair. No warning until there was no radiator fluid left and overheated and had to pull over on the highway. Radiator was cracked in 5 places. 4 year old car, less than 55,000 miles. Confirmed and repaired by an independent service center.

NHTSA ODI 11681147

Coolant bypass valve problem with several rav4s. My car is unusable and I need it to work.

NHTSA ODI 11672368

While parked in a commercial lot on [XXX] around [XXX], I noticed smoke coming from the front of the vehicle while sitting inside. There was a strong burning rubber smell. I exited and saw flames coming from beneath the front left bumper, directly under the fog light area. I had arrived at the location about 30 minutes earlier. I opened the hood from inside the vehicle, stepped back, and called 911. The fire rapidly engulfed the front of the vehicle. Firefighters arrived within 10 minutes and extinguished the fire. Police responded and created a report. Three nearby vehicles also sustained fire damage. The vehicle had previous front-end repairs (driver side bumper and fog light) and was well maintained. The vehicle had not shown any warning lights or messages prior to the fire. I believe the fire originated from an electrical or engine component and the vehicle is available for inspection upon request. GEICO insurance has been contacted and a claim has been opened. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11666206

"What component or system failed or malfunctioned, and is it available for inspection upon request?" Coolant bypass valve is malfunctioning. "How was your safety or the safety of others put at risk?" unknown "Has the problem been reproduced or confirmed by a dealer or independent service center?" Service manager at Tuscaloosa Toyota confirmed problem without even inspecting the vehicle. He told me I am not the only Toyota customer experiencing this problem. "Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others?" Vehicle nor component has been inspected by manufacturer. "Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear?" Warning alert that reads 'engine maintenance required' has been appearing on the vehicle's dashboard for over a year now.

NHTSA ODI 11664314

Steering power low message appears and engine completely stops.

NHTSA ODI 11662210

Pop up of "Engine Maintenance Required" , ran the diagnostic steps and confirmed it is due to coolant bypass leak.

NHTSA ODI 11660869

Coolant Bypass Valve The problem has been confirmed by the dealer Warning: Engine Maintenance Required

NHTSA ODI 11659254

While turning slowly, right tun, into a parking space, the vehicle lunged forward at a much higher speed than anticipated. The vehicle jumped the sidewalk, went up an embankment, about 20 degrees, and about 25 feet until it stopped on its own. Happened on April 14th, 2025, about 11:30 am. Driver was is good health, no medical conditions. Driver also has a clean driving record, no infarctions. The vehicle jumped a curb 4 inches high, ran over some light brush, but luckily no damage to vehicle. There are train tracks about 15 feet away, which could have been another incident. Driver says when she slowly pulled into the spot, the car lunged forward, with good thrust, and I am a witness to this incident.

NHTSA ODI 11655028

Several malfunction warnings (pre-collision system malfunction, AWD malfunction, engine malfunction, parking brake malfunction) as well as several warning lights appeared on my dash. Took vehicle to a Toyota dealership for repairs. Fuel pump was replaced. Drove car a few days later and all the same warnings and lights came back on and this time the vehicle stalled in the middle of the road while driving. Was able to restart but had as soon as vehicle was stopped it would stall. Had to restart the vehicle several times while driving 2 miles just to get it home.

NHTSA ODI 11652913

Keep getting an service engine maintenance message/ check engine light. No codes show up, most likely the coolant bypass valve everyone is having an issue with. Don't receive message when ac is off. Or when blasting heat. Reset and comes back. Needs to be a recall. I see there is a class action lawsuit pending.

NHTSA ODI 11613606

Started seeing the message on the dashboard that says “engine maintenance required visit your dealer” when I took it to get it checked out they said it was the coolant bypass valve, the worker at the Toyota dealership mentioned that it has been happening to other vehicles as well, so he knew exactly what the message meant. Upon doing my own research I found many others with the same issue on their RAV4’s as well. This issue is not covered by their warranty

NHTSA ODI 11610767

I own a 2021 RAV4 which I routinely get serviced at the Passport Toyota. On June 29, I took my car to Passport Toyota for service because the maintenance required message appeared on my car’s dashboard. The service advisor texted me a list of recommended services for my RAV4. One of recommended services was to replace the coolant bypass valve. I agreed to the service at $800. On July 3rd the check engine light came on and the car begin to overheat. I was 2 miles away and immediately drove there to inform them of the issue. They checked my car in for service, and explained to me that a hose must have come loose and was the cause of a coolant leak. When I received my vehicle, the check engine light was off, and the car seemed to be in working condition. On July 23 the maintenance required message returned. Again, I immediately drove my vehicle to the dealership and checked it into the service department. My service advisor notified me that they needed to reset the maintenance required message, and it would go away. I received my car back and the maintenance required message was no longer there and seemed to be in working conditioned. The next morning, July 24 while driving to an appointment, my car started to overheat and the check engine light came on again. This time the car was smoking. I was less than 5 miles from the dealership so I took it back to the them and checked it in for service. After having my car in for service for one week, they called me and stated that the issue was related to me having blown a head gasket, and I would need a new engine. The service department continued to do test as required by Toyota to determine the cost of a engine and how much they would cover. Three weeks later, they told me that Toyota will pay half the cost and I have to pay $3200 out of pocket with only about year warranty. I brought my car in several times and clearly mistakes and misdiagnosis were made on their part which led to the destruction of my vehicle.

NHTSA ODI 11610447

We’ve had the car for three months had it to the shop of the Toyota place seven times for the electrical issue the car will shut off going down the road when you give a gas when you let off the gas, it will start back up spitting sputter, the instrument cluster The gauges will stick in one spot and not budge and you lose all power to the vehicle to drive

NHTSA ODI 11592479

A warning message came up that the HYBRID SYSTEM MALFUNCTION contact dealer. This was confirmed by the dealer. According to the dealer and message boards at various web sites, the Hybrid System Malfunction is NOT uncommon. To fix the problem, a wire harness must be replaced with a replacement cost of $2000-$4000. When I asked what changes have been made to the replacement part to address the corrosion problem, the response was there might be a new coating but we do live in New Hampshire.

NHTSA ODI 11589893

Engine maintenance light came on saying to go to dealer at 35,000 miles. The coolant bypass valve needs to be replaced in order to prevent the engine from overheating. Our repair shop coordinated with the dealership who admitted that they commonly see this issue on RAV4 and Corolla models, though there is no recall currently in place.

NHTSA ODI 11585965

I received an error message “Engine stopped, steering power low” after driving an hour in the rain, sat in my car for about 20 mins with wipers on, engine began to jerk aggressively then shut off. I could not gas it or move the car. I let the car sit after being towed, it ran fine as if nothing happened. I got a battery test and it was at 100% charge according to Autozone. The check engine light, battery light and steering light came on. No prior indications of this problem.

NHTSA ODI 11581454

Coolant Bypass Valve failed.

NHTSA ODI 11580299

I had my 2021 RAV4 Hybrid in for a routine oil change at 59,150 miles. I have maintained this vehicle in accordance with Toyota's recommendations since purchasing it brand new. During their inspection, it was noted by the Toyota mechanic that the timing cover was already seeping, way before it ever should be for this age and mileage of vehicle. The dealership mechanic did not recommend anything be done at this time since it wasn't an "active leak", even though seepage will turn into a leak. They denied my request for them to inspect the gaskets and look for cracks in the timing cover while my vehicle is still covered under warranty. While they would not say why they refused to honor my request, I assume it is because my warranty is set to expire when my vehicle reaches 60,000 miles (only 850 more miles from then) and they want me to have to pay $3500 of my own money instead of theirs after my warranty expires. It is unsafe for me to continue to drive this vehicle due to the fact that a timing cover leak can be a serious issue for my vehicle. The timing cover helps protect the timing belt, which is crucial for the proper operation of the engine. If the gasket is leaking, it can lead to oil loss, potential engine damage, and even engine failure if not addressed promptly. There were not any warning lamps that indicated to me that there was an issue.

NHTSA ODI 11564723

The engine block cracked and started leaking coolant. It is clearly a defective manufacturing of the block casting. The same engine was recalled several months before mine, but my manufacturing date fell just outside of the range they recalled in the same year. The problem was confirmed by Price Leblanc Toyota in Baton Rouge, LA, a new short block was installed and I was left footing the bill because Toyota Corp denies responsibility for it even though it is only 3 years old and has had ALL maintenance done through the dealerships. The initial coolant leak was first noticed on 10/17/2023. The vehicle repairs were completed by Price Leblanc Toyota and picked up on 12/13/2023.

NHTSA ODI 11563342