Toyota RAV4 Owner Says, “After I Get Gas I See Warning Lights and It Shuts Down, Dealer Blames My 28 Cent Overfill, Am I Crazy For Thinking They Are Full Of It?”

You'd never guess what 28 cents of overfilled gas allegedly did to this 2022 Toyota RAV4: smoke, rough idling, a shut-off, and a mystery dealership diagnosis. Here is Sierra's unbelievable story.

Sierra Szymoniak on the Toyota RAV4 Discussion Group 2019-2025 - Gas + Hybrid + Prime Facebook page says, 

"Ok, I figured this would be the best place to ask this question. I recently bought a new-to-me 2022 Toyota RAV4 XLE. I bought gas today, and the pump shut off at 28.22, and I took the total up to 28.50. I then drove 15 minutes down the road and parked in a parking spot, and didn't shut the car off." 

"I then noticed a little bit of smoke coming from the front right of my hood. I thought nothing of it because it was raining pretty decently. I shifted into reverse, then into drive, and the car started idling roughly and then shut itself off. I went to start it up again, and it did the same thing, but this time with the engine light coming on, and it said the power steering fluid was low." 

"I had it towed to my dealership, and they couldn't get it to replicate what it had done to me. They blame me because I pumped 28 cents after the first click, and they say that was likely the cause. Am I crazy for thinking they are full of it?"

Did $0.28 of Gas Shut Down This RAV4?

This week, we're addressing a fascinating, if frustrating, question from Sierra's recent ordeal.

Sierra describes a sudden cascade of problems right after refueling: rough idling, a complete shut-off, mysterious smoke, and a baffling low power steering fluid warning. The dealership's diagnosis? Blame the 28 cents worth of gas pumped after the nozzle's first click.

Sierra should question the dealer's diagnosis.

While the dealership is technically correct about the danger of overfilling, simplifying a multi-symptom electrical and mechanical failure into a minor user error is simply unacceptable. First, let's dive into what causes the Toyota RAV4 XLE engine trouble after overfilling the gas tank and look at the strange secondary warnings.

The EVAP System's Critical Role

The core of the dealer's argument hinges on the Evaporative Emissions Control (EVAP) system, as it plays a critical role. Its sole job is environmental: capture hydrocarbon vapors from the fuel tank and meter them back into the engine to be burned.

To do this, your RAV4 relies on a component filled with activated charcoal—the charcoal canister. This leads to a great question that many gas car owners have:

Is it safe to pump gas after the first click on a Toyota RAV4?

No. When you 'top off' the tank, you flood the vapor recovery lines, forcing liquid gasoline into the canister. Charcoal is used for vapor absorption, but liquid fuel completely ruins it, turning it into a sludgy sponge.

Connecting the Engine Symptoms

Sierra's immediate symptoms—Rough idling and shutting off on her 2022 Toyota RAV4 XLE—are the textbook outcome of a flooded canister. When the engine's computer attempts to purge the stored vapor via the canister purge valve (a critical part of Understanding the Toyota RAV4 EVAP system), it inadvertently pulls liquid gasoline directly into the intake manifold.

This liquid gasoline creates an intensely rich mixture, instantly fouling the combustion process. The engine chokes on the raw fuel until it stalls completely. This event immediately sets a severe Diagnostic Trouble Code (DTC) in the powertrain control module (PCM), which is why the Check Engine Light appeared.

So, the dealership's claim that overfilling gas caused the check engine light on the RAV4 is possible, but it addresses the symptom rather than the resulting damage.

What About That Smoke From Under the Hood?

Here is the real meat of the mystery: the smoke from the front right and the power steering warning. These symptoms seem disconnected from a simple EVAP issue, suggesting a cascading failure or coincidence.

1. First, the smoke. Diagnosing mysterious smoke from the front right of the 2022 RAV4 hood is complicated. The EVAP system is usually far from the exhaust manifold in that location. The most likely scenario is that the sudden engine shake and shut-off caused a nearby hose (coolant, oil, or a washer fluid line) to vibrate, leaking a few drops onto a hot component. Given the heavy rain mentioned, this is a distinct possibility.

2. Second, there is a Power Steering Fluid Low warning on the 2022 Toyota RAV4 after refueling. The 2022 RAV4 XLE uses a modern Electric Power Steering (EPS) system—it has no fluid! This warning is a classic "ghost" message. When the engine stalls unexpectedly due to the flooded EVAP system, it causes a momentary, severe drop in system voltage. 

This electrical hiccup can corrupt data in the vehicle's computer modules, causing the Body Control Module or Instrument Cluster to display a nonsensical, default, or irrelevant fault message. The fact that the dealership couldn't replicate the issue supports a transient, electrically induced fault rather than a physical fluid leak.

Conclusion and Practical Takeaways

Sierra is not crazy. She likely caused a failure mode in the EVAP system by overfilling the gas tank. However, the resultant problems—engine stall and system fault warnings—indicate a system designed without adequate safeguards against this common owner habit.

What Should Sierra Do Now?

Insist that the dealer focus their diagnosis on the EVAP system, specifically checking the condition of the charcoal canister and purge valve. Even though the canister appears dry now, it was saturated during the event and must be replaced to prevent recurring CEL issues and poor performance. 

For the strange warning and smoke, monitor the vehicle closely, as the initial incident may have been a one-off electrical anomaly caused by the engine dying.

A Question For RAV4 Owners

Have any other RAV4 owners experienced their vehicle breaking down, smoking, and throwing an engine light simply because they "topped off" the gas tank with a small amount after the pump's first click, as this dealership claims?

Check out my 2024 Toyota RAV4 story: I Just Did the 15K Oil Change On My 2024 Toyota RAV4, and 5K In, the Oil Was Filthy, Never Go 10K as Recommended By Toyota

I am Denis Flierl, a Senior Torque News Reporter since 2012. My 30+ year tenure in the automotive industry, initially in a consulting role with every major car brand and later as a freelance journalist test-driving new vehicles, has equipped me with a wealth of knowledge. I specialize in reporting the latest automotive news, covering owner stories, and providing expert analysis, ensuring that you are always well-informed and up-to-date. Follow me on X @DenisFlierl, @WorldsCoolestRides, Facebook, and Instagram

Photo credit: Denis Flierl