2020 Toyota RAV4 Fuel System Problems

Mileage when the problem started

• Under 25k
  57100%
• 25k–50k
  00%
• 50k–75k
  00%
• 75k–100k
  00%
• 100k–150k
  00%
• 150k+
  00%

Owner reports

Selected complaints filed with NHTSA by 2020 Toyota RAV4 owners, lightly cleaned up (personal details are redacted by NHTSA).

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. …

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. …

While driving on the highway, the vehicle suffered a sudden loss of engine power and went into a low-power/vapor lock state due to severe fuel starvation. This created a major safety hazard by stranding the vehicle on the highway shoulder and exposing occupants to high-speed traffic. Prior to the power loss, there were no advance warning lights until the engine stalled. A diagnostic scan performed immediately following the incident confirmed code P0087 (Fuel Rail/System Pressure - Too Low), along with cylinder misfire codes P030027 and P030100. To allow the vehicle to safely limp home from a remote location, an independent technician cleared the diagnostic trouble codes. An independent scan tool report clearly documented and confirmed the low fuel pressure fault prior to code clearance. …

-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. …

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,

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.

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.

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"

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.

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.

Related recalls

Fuel System complaints in other RAV4 years