Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2021 Toyota RAV4 owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2021 Toyota Rav4. The contact stated that while fueling the vehicle, the fuel tank failed to register the correct fuel level. The contact stated that the fuel warning light illuminated intermittently while driving and while the vehicle was parked. Additionally, the fuel gauge displayed inaccurate readings and eventually became inoperable, leaving the contact unaware of when the vehicle needed to be refueled. The vehicle was taken to the dealer for inspection. The dealer informed the contact that the fuel tank readings had failed, and the vehicle was supposed retain approximately 14.5 gallons of fuel; it would only accept approximately 11.5 gallons during testing. The contact was further informed that the fuel tank and fuel reader had failed and needed to be replaced. The vehicle was not repaired. …
While accelerating ~6ft from a complete stop, a minor collision occurred affecting the front right headlight. The air-bags did not activate and the engine compartment was immediately on fire. Within ~1minute, the fire had spread to and completely engulfed the passenger compartment. The contents were immediately destroyed. The speed with which the fire spread through the vehicle was a significant risk to my life and the motorists around me. There were no warning lights on the dashboard prior to the incident, and the car had never before experienced an accident. Witnesses and firefighters estimated that any fire barrier between the engine and passenger compartments had failed, and that a fire of that severity from such a minor accident indicated some fault with the vehicle. The vehicle was an immediate total loss as inspected by our insurer.
The contact owns a 2021 Toyota Rav4. The contact stated while driving at an undisclosed speed, there was an abnormal fuel odor in the vehicle. The vehicle was taken to the dealer to be diagnosed. The mechanic was unable to determine the cause of the failure. The manufacturer was not notified of the failure. The failure mileage was 7,500.
2021 RAV4 Hybrid exhibits fueling problems, consistently. Parked on level concrete, shut off, in "Refuel" status, at the fuel island, it dependably suffers abject failure at attempts to refill the gasoline tank at the fuel pump. With the fuel pump nozzle set to lowest flow setting, at any moment, the fuel being pumped down the filler tube surges back up the filler tube, occasionally spilling out onto the side of the car and the ground. Other times, with the pump nozzle set to lowest flow settings, it may automatically and arbitrarily shut off after 1 gallon or 4 gallons, when the miles driven along with the fuel gauge indicates the tank requires at least 10 gallons. It is impossible to know from one fill-up to the next fill-up if the tank is full, close to full, or several gallons shy of full. …
Vehicle stumbles on moderate acceleration from slow speed, hesitates shifting also. Problem has persisted since new. Dealers rep "they're all like that. can't find any problem. No warning lamps. I think there is a TSB but it seems well hidden. I feel it is a safety issue - acceleration from low speed compromised. We have 2 more 2021 rav4s in the family that do not do that. I believe Toyota knows about this problem. Also had a problem with vehicle slamming violently into lower gear when coming to a stop. Dealer could not find problem. I checked vehicle and found air filter housing not properly secured. I latched it properly and that seemed to solve slamming into lower gear problem. Dealers mechanic (?) must have not latched it properly after 12 month service. No telling how much dirt was sucked into engine while that was happening. …
I purchased car in 12/20. The car has a 14.5 gal sized tank, and gets avg 42 mpg -calculated by miles driven to empty divided by gas pumped when empty- as well as on dashboard display. Since purchase the car registers empty 150 or more miles sooner than the 560 dashboard estimate and than 14.5*42 mpg. I am only able to fill less than 11 gallons when the fuel Guage reads empty with less than 20 miles remaining. The service dept assures me the car is able to drive 560 on a full tank, as the fuel Guage and miles-to-empty ignore a "buffer " of several gallons in the tank. It is unsafe to drive over 150 miles with the car registering no miles remaining. It is unsafe to plan a trip based on dashboard or tank size/gallons mileage, where I could run out of gas in an unsafe region.
Since buying this 2021 Toyota RAV4 Hybrid vehicle in 12/2020 gas tank only takes about 10-11 gallons of fuel when refueling , whereas tank capacity is 14+gallons. This leads to trickle filling to get a full tank which Toyota advises against as unsafe. Toyota has agreed to pay for fixing this manufacturing defect for 2020 model RAV 4's with the same manufacturing defect, but so far Toyota holding back issuing authorization to fix the 2021 RAV4 Hybrids . Car available for inspection upon request. Toyota dealer wants me to pay for diagnosis, manufacturer unwilling to pay for inspection of this safety risk despite paying for it in 2020 RAV4's with same defect.
Toyota of Portland sold me a used 2021 RAV4 hybrid XSE with a defective gas tank. The gas tank does not carry the 14.5 gallons as advertised, the gas gauge cluster is inaccurate, and the mileage remaining on the dash cluster is inaccurate. These defects were not disclosed to me prior to the sale. Immediately after seeing the problem, I brought the vehicle in for service at Vancouver (WA) Toyota. They botched the repair job and the vehicle is emitting gas vapors non stop. Over the weekend, my house was inundated with gas vapors and my household and I experienced dizziness, irritability, poor eyesight, and nausea.
2021 Toyota REV4 with just over 5,000 miles. I got off from a parking lot and drove 1/2 miles, The screen shown "Vehicle Alert" and asked to check engine with message "A malfunction in the electronic control of the engine, throttle, or automatic transmission has been detected". I smell very strong gasoline, then stop the vehicle. I check the gas tank, it's normal. I opened the hood and saw a puddle of gasoline on engine part, between the battery and the engine but lower than the battery. It's so dangerous to drive with leaking gasoline so I park my car on a street
I was pulling into a parking space with my foot on the brake, had just touched the parking bar, and the engine started racing. The car went forward over the parking bar before I cold stop it by stomping on the brake. The only thing stopping me from going over the side of the hill was a chain link fence. Luckily the brakes worked. This is a 2021 RAV4 and I have never had this problem before. I am scheduled to go into the Toyota dealer to have them look at it.
Fuel System complaints in other RAV4 years
Frequently asked questions
How common are fuel system problems on the 2021 Toyota RAV4?
NHTSA has 24 complaints about the fuel & propulsion system of the 2021 Toyota RAV4, 6% of the model year's 387 complaints. The component named most often is storage (1 mentions).
Is there a recall for 2021 Toyota RAV4 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2021 Toyota RAV4, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2021 Toyota RAV4 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 1,000 miles, and 86% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.