Gas Tank Issue for Toyota RAV4 Hybrid: Here is Your Fix (with Video)

Just had my fuel tank changed for the second time and the fuel gauge changed as well, the fuel indicator reads full now but im only getting 11 gallons of fuel when completly empty(5 miles to empty on the display). When filled the distance to empty only reads about 410 miles. I asked Toyota about it and they told me its fine and correct, but why is it not in the 500s like it should be? Have you guys had that problem as well? Thank you.

Dear Jeff, Our 2020 Toyota RAV4 Hybrid XSE had this problem. I found that I could fill the tank by setting a refuel auto shutoff to the lowest flow rate, then add about 1 gallon more. I was afraid of trying to do too much for fear of contaminating the vent filters. When I read that a fix had been devised I called my Toyota dealer who booked a repair to coincide with my 1-year service. The service bill lists the parts replaced as a Fuel Gauge Assembly, Fuel Suction Gasket, and Fuel Tank Sub-Assembly. The service writer mentioned the last was a fuel bladder. They completed this work, plus the oil/filter change & multi-system checks in under three hours. As we only had 4,400 miles on the year-old car, I had not refueled enough for it to have been a big irritant. I am, however, glad it is done. Thanks for your reporting and reviews. I am on my 4th Toyota and have not looked back since buying the first. I love the reliability but really wish Toyota would improve their Electronic/Driver interface. It really needs help.

I have a 2018 hybrid Rav4 Limited that has this same issue. They say my VIN indicates that I am not eligible for a fix and yet I cannot fill my tank to more than 11 gallons in what is supposed to be a 14 gallon tank, even when the low gas light is on and I supposedly have 20 miles more to go. I always thought that my calculations for how much mileage I should get between fill ups was not right.

Are there any other steps to take? The dealership told me that if they find a problem I'd have to pay to get it fixed. But if this manufacturing issue affects other Hybrid RAV4's it seems to me that they should expand this coverage. Is anyone with one prior to the 2019 model year with this problem?

Toyota needs to fix their system key malfunction issue with their vehicles! So many people having this issue and Toyota is not giving a crap!!! Be better Toyota! We buy your vehicles because of reputation and your rep is tanking.

I have a 2019 RAV4 XSE, and have had this issue since brand new. I have inquired of my dealer at least six different times, and told that filling the car and getting only 10 gallons in was normal, and that there was a larger reserve.

I am so happy to see that they finally are acknowledging that there is an issue! Cannot wait to call them first thing Monday! Huge thank you to Torque News and Ali!!

I used to be able to get 8.5 gallons into the tank. It took a lot of work to get there. I got my tank fixed. I can now get 13 gallons into the car. Once the pump kicks off I can get another 1.5 gallons in. So it stays at full for a long time. Big improvement.

My 2021 XLE rav4 hybrid has the same symptoms. Havent even hit 5,000 miles yet.

Near empty, it only takes 10 gallons. Its supposed to hold about 14.

This issue IS starting to crop up in the 2021 Venza. Posters here as well as on the Venza forum at Toyota Nation are starting to report only being able to refill 7-11 gallons when almost empty. This is disappointing and a real deal breaker. If Toyota is unwilling to put the time and effort in to coming up with a real solution to this issue, people should simply stop purchasing the Hybrid versions of the RAV4, Venza, and Highlander (from what it sounds like it is affected as well.) When the unsold vehicles start piling up on dealer lots Toyota will have no choice but to engineer a permanent solution and retrofit it to existing cars as well. This is simply unacceptable.

2021 Venza. Love the vehicle buy never get more than 720km (~430 miles) expected from a full to the brim tank. Typically I add 8L after it clicks off automatically, once I got 10L more added. Taking car in for first oil change tomorrow, will see what they say.

What a mess Toyota has on their hands. I would be passed if try to go more than 300 miles on a highway trip i would to stop and refuel.

I have a 2020 Toyota RAV4 hybrid. Did the repair via the consumer service program and still could only refuel to 10 gallons. Took it back in to be looked at and was told since it is above 9.8 gallons it is operating up to manufacturers standards. If you, like me, are upset with a less than advertised fuel tank there is a class action lawsuit that has been filed in California that you can now join lead by Schubert Jonckheer and Kolbe law firm. I am not affiliated with this firm in any way outside of contacting them about the lawsuit.

When I inquire about the gas tank issue, the dealer gives me a dumb look and says they are working on it. Its been two years. When will they stop working on it and fix the gas tank? If I bounce, cuss and play with the gas nozzle for ten minutes, I can get 8 gallons in it. Not handy for road trips. The "Miles to empty" read out is pure myth. I would gladly join the class action lawsuit.

I brought my Rav4 in they replaced the gas tank and I'm still having same issue. They are telling me that there is 3 gallons of reserves in the car blah blah blah. I'm so heated. This situation is turning me off to Toyota.

If there is a issue with gas tank it should affect all the vehicles with same tank unless gas tanks made by hand and each tank different?

I have a RAV4 Hybrid LE 2020 with the tank issue. It’s the third time local dealer in Puerto Rico try to fix the problem without success. I could refuel the tank until 10 gals or 42 liters the dealer says if I try to fill up to 14.5 gals I could damage other components of the fuel system and the difference in fuel its in the reserve. I can only get 460 miles per full tank. Toyota doesn’t have a true intention to fix this problem. I am still waiting for Toyota Customer Service to contact me with a resolution of my case. They request me some extra time to understand my case had been three week and no formal response from them yet. Very disappointed about this I bought this car for being more conscious about the environment and for the MPG of Toyota Hybrid media campaign.

Has the gas tank issue for the Rav4 Hybrid been resolved for the 2021 model year. I am considering purchasing one very soon.

Has the gas tank issue for the Rav4 Hybrid been resolved for the 2021 model year. I am considering purchasing one very soon.

I have received the letter, but I feel they don't want to repair it for me. I have made an appointment for two times. The first time when I arrived, the dealer said that the certified technical worker was not there, and he didn't make an appointment for me until today. But today I went to the dealer and they said they couldn't repair my car because they had so many cars to repair. It's strange that they have made an appointment for me today, but they can't do the test today. Now the dealer has made an appointment for me next Thursday. The every time I was there they all said there were no problems with the vehicle and they had never heard of any problems, even though I had a letter from Toyota.

I have a 2021 XSE and noticed this immediately. The range off the lot brand new displayed 580mi and I was ecstatic as this is why I purchased the car. The first fill at the pump came after reaching the gas light illuminating empty and then I only got 380mi. After carefully monitoring this I knew I had the issues described above. The problem is, my Vin didn't qualify under the "campaign" and Toyota would not fix it based on the vin. I own a $38,000 car brand new and getting a range nearly 60% of what I thought would get when purchasing the new vehicle.

Bought a 2020 RAV4 Limited in Aug 2020, and have had this problem from the beginning. But, due to the pandemic, I wasn't driving much and just decided to live with it. Then, on my last fill-up, the pump kept clicking off every 5 seconds. When I finally got 9 gallons in, I started the car and the fuel gauge stayed at 1/4. I drove around for a while, but the gauge remained stuck. When I got home, I made an appointment with Toyota for the next week. When I brought it in, they looked it up online and told me they would fix it, no problem. 5 and a half hours later, it was ready and is working fine. New fuel tank, sending unit, and gasket. I am very pleased with Toyota's warranty service on this.

I was having this issue on my 2019 certified used RAV4 Hybrid I bought in Feb 2021. From low indicator to the fuel pump click, I could add about 8-9 gallons. My local dealer had me bring in the RAV4 on a full tank and they checked the actual level (I guess it wasn't enough to check the vin.) They agreed that my car was included in the "support program". It took about 3 weeks for the parts to come in. They replaced the fuel suction gasket, fuel sender gauge assy and fuel tank sub-assy. Took most of a day BUT what a difference. I filled it from about 1/4 tank to pump click, it took 11.5 gallons. My DTE is 585 mi . I think my best previous DTE was 430 mi. So yea, the fix seems to have resolved the issue.

Took my 2020 Rav4 Hybrid to the dealership two weeks ago, they swapped the fuel tank and the sender gauge. Drove my car until it said it has about 11 miles left and filled it up 14.7 gallons. Seems like they definitely fixed the issue but i'm just a little concerned if that's an overfill...

Just picked up my new 3021 RAV4 xle premium the first of July 2021. It has the gas tank issue. Will they handle this at
Toyota? Also why is it an issue for a brand new car?

I have a RAV4 prime, the dealership just ordered me a new gas tank and required components to correct the issue. The car wouldn't hold more than 42 L without the gas spewing out. Just talk to your dealer, they essentially get paid by Toyota to fix the problem when it's under warranty .