619 of the
12,161 complaints filed about the Toyota RAV4
are about the fuel system —
5% of everything owners reported.
The worst model year for it is 2019.
While driving in the mountains on a hot day, the car suddenly reported numerous faults, including check engine, parking brake malfunction, pre-collision system malfunction, AWD system malfunction, and secondary collision brake system malfunction. The car lost power and forced us to pull over on the side of a dangerous mountain highway. We powered-off the car for a few minutes and started it again and were able to proceed to our nearby remote mountain destination without another loss of power, but the faults remained. The next day we were able to get the car to a nearby NAPA store to read the check engine codes, which there were only 2 of the "P0087" code. I had them clear the fault codes in order to be able to safely drive the car (~120 miles) back home. Some quick research shows a known issue and TSB for that in our exact high-altitude and high-temperature situation - Toyota T-SB-0058-22, related to a known design flaw with the ECM and fuel suction tube. Luckily, it did not throw the errors again during our drive home. I made an appointment at our local AutoNation Toyota Arapahoe for the following week. I detailed the issue and provided pictures of the errors - including the code reader display. The dealer claimed to not find any issues and refused to address/execute the TSB, stating that the code must be active and present in order for them to fix it and that my pictures were not sufficient proof. I explained that it was an unacceptable safety risk to have left the car in that state and that the issue is known to only occur in certain conditions (e.g. high-altitude, high-temperature mountain driving). Issue remains un-addressed, which is highly unacceptable and poses a serious on-going safety risk.
NHTSA complaint #11758893 — an unverified report by a vehicle owner.
On August 6 2026, my RAV4 just cut off at the traffic light. The car was completely dead. I was unable to unlock the trunk but the doors did open. The vehicle was towed to the local dealership. The tow truck man hooked up his portable car charger and the car started. On August 8, 2026 the car cut off after parking in a parking space and would not start so I had to get a jump off. After driving for approximately 50 miles to home, I got a low voltage warning and a statement the battery is charging. The local Toyota dealership did a diagnostic test on August 11, 2026 and stated the battery, starter, and alternator were okay. The same thing happened again on August 12, 2026. The car just cut off after stopping in the parking lot. After getting a jump off, I received a message that the battery is charging. Also, the car shifts speed while driving.
NHTSA complaint #11756623 — an unverified report by a vehicle owner.
UPDATE TO PRIOR COMPLAINT — Filed April 2, 2026. VIN: [XXX] . 2014 Toyota RAV4 AWD XLE. Team Toyota Langhorne, 746 E Lincoln Hwy, Langhorne PA 19047. Vehicle remains out of service — 53 days as of April 10, 2026. SECOND REPLACEMENT VEHICLE — April 4-5, 2026: Dealership presented 2014 RAV4 VIN [XXX] as replacement. Upon visual inspection: valve cover leaking; blue silicone sealant on valve cover applied unevenly indicating prior engine disassembly or concealed active oil leak; catalytic converter flanges rotted top to rear requiring full replacement; oil on bottom of motor. Photographs available. Dealership declined to repair at estimated cost of $2,500 — April 6, 2026. DEALER RESOLUTION FAILED — April 7, 2026: Bill Sullivan, Pre-Owned Sales Director, offered buyback or trade. Both rejected as inadequate. No resolution provided. Two defective replacement vehicles presented — neither acceptable. Cases: [XXX] / [XXX] / [XXX] [XXX] — [XXX] — [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11730513 — an unverified report by a vehicle owner.
My 2025 Toyota RAV4 (39,919 miles) has a permanent "Check Engine" light. On March 18, 2026, diagnostic codes P24517F and P214502a were found, indicating a failure in the switching valve and fuel tank pressure sensor. Toyota USA and the dealer are refusing to honor the 60,000-mile Powertrain Warranty and Federal Emissions Warranty. I am reporting this as a safety defect because the vehicle may lose power or stall on the highway, creating an immediate crash risk. The manufacturer's refusal to repair a known emission/fuel defect in a new 2025 model has left me with an unsafe vehicle for over 15days.
NHTSA complaint #11728745 — an unverified report by a vehicle owner.
SUPPLEMENTAL TO COMPLAINT ID: 11728745. My 2025 RAV4 failed at 39,919 miles. Toyota Corporate is acting in bad faith to deny the 60,000-mile Powertrain Warranty. The Case Manager repeatedly calls only after 6:30 PM when the dealership is closed to avoid resolution. Furthermore, the representative is now using "legal threats"-directing me to their legal department-as a tactic to stop me from pursuing this valid warranty claim. This is a safety hazard and a violation of federal warranty law.
NHTSA complaint #11728938 — an unverified report by a vehicle owner.
The vehicle exhibits a consistent and reproducible malfunction in the powertrain system, specifically related to acceleration response and drivetrain engagement. While driving at a steady speed, when the accelerator is pressed gradually (approximately 50–60%), the engine RPM increases but the vehicle does not accelerate accordingly. There is a delay in power delivery. When the accelerator is released, the engine may continue revving briefly, followed by a sudden and jerky engagement of the drivetrain. This issue occurs consistently under the same driving conditions and can be reproduced every time. The vehicle is available for inspection upon request. This malfunction creates a safety risk when merging into traffic, entering intersections, or making turns. The vehicle does not respond when acceleration is required, which can lead to dangerous situations where other vehicles may approach at higher speeds. After the delay, the vehicle may surge forward unexpectedly, increasing the risk of collision. The issue has been reported to multiple authorized Toyota dealerships on several occasions within the first 15 months of ownership. The vehicle has been inspected by dealership technicians, but the concern has not been diagnosed or repaired. Dealerships have stated that the behavior is normal, despite the repeatable nature of the issue. No warning lights, error messages, or diagnostic indicators have appeared at any time. No diagnostic trouble codes have been reported. The vehicle is equipped with an 8-speed automatic transmission, and the behavior appears consistent with a possible transmission, torque converter, or drivetrain control malfunction affecting acceleration response. The condition is not related to driver input and occurs under controlled, repeatable conditions.
NHTSA complaint #11726160 — an unverified report by a vehicle owner.
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. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for further assistance. The approximate failure mileage was 46,252.
NHTSA complaint #11721491 — an unverified report by a vehicle owner.
I was driving home in the rain for about 75 minutes and when I arrived in my driveway I saw steam coming from the front grille area. It wasn't due to a high engine coolant temperature so I decided to carefully open the hood and check for the source. I saw water inside the bottom of the engine bay behind the radiator steaming from the heat of the engine. A few seconds later, the engine stalled and the following message appeared: "Engine Stopped, Steering Power Low" which came on with a check engine light, red battery light, and steering light. I used my scan tool and obtained the code: P0171, System Too Lean. After doing research, I've come up with a conclusion to the potential cause. Starting with the 2022 model year RAV4 non-hybrid (and onwards to the 2025 model year RAV4), the air intake inlet was redesigned from the prior one in the 2019-2021 RAV4 non-hybrid models, as seen in numerous comparison images online. This new design presents a dangerous fault. When driving in rainy conditions, especially at higher speeds with mist kicked up from cars in front, the air intake will take in water. The water will flow to the air filter and then reach the Mass Air Flow sensor (MAF). The MAF sensor monitors the amount of air entering the engine and sends signals to the car's computer to help determine how much fuel to send to the engine to maintain an ideal ratio for optimal efficiency. Considering that water is getting to the MAF sensor, it thinks that the water is excess air, so less fuel is sent to the engine as a result. Since I came to a stop in my driveway, the engine is now at its idle speed and only commands a small amount of fuel to remain running. Now, when combined with the water, that lower fuel flow is practically cut off, leading to the stall. This happened to me before when driving in the rain, but in more dangerous conditions in stop-and-go traffic. Toyota must follow up on T-TT-0763-24 because it has been well over a year since their initial investigation.
NHTSA complaint #11719600 — an unverified report by a vehicle owner.
I have had multiple instances where the vehicle has failed to accelerate when making a left hand turn. Each time this has occurred, my car has rolled into the intersection from a stop at a small decline, but the gas seems to do nothing. My car silently rolls forward and then I have no power or gas and am trapped with no acceleration. I’m worried this is going to get me into an accident and seriously injured. It does not happen super often, but enough that I know there is a problem. Dealer has not been able to see any codes, and we have not been able to recreate the issue in front of the service advisors.
NHTSA complaint #11711581 — an unverified report by a vehicle owner.
Vehicle consistently accepts only approximately 9–10 gallons of fuel when the fuel gauge indicates empty, resulting in significantly reduced driving range. Issue has been widely reported by other Toyota RAV4 Hybrid owners and appears related to fuel tank design. Manufacturer declined assistance and referred responsibility to selling dealer despite known complaints.
NHTSA complaint #11709358 — an unverified report by a vehicle owner.
1)I purchased my car during daylight hours. A few days later I drove my car in the evening and could not see street signs or the road 1/3 of the way up through my windshield. There is a definitive line where the windshield turns black. It is extremely dangerous. The Toyota engagement center told me to take my car to the dealership where it was purchased. I also took photos of what I could not see while driving. The dealership said there is nothing they can do and this is normal. The engagement center called back after they received the photos and told me their head technician could not see the street signs looking at my photos either. I was told to take the car back again to the dealership and once again told " there is nothing that can be done." They told me to put on my automatic brights. This feature does not help. The dealership also told me I could just put on my brights manually. This blinds other drivers on the road and then they put on their brights driving towards me, which decreases my ability to see while driving. the Toyota engagement center dropped the ball after 3 months of trying to report how dangerous this situation is. I am now reaching out to your department because of serious safety issues. I did not buy a car to be placed in a dangerous situation where I can't see to drive at night up. It is very dangerous driving up and down hills. 2)I also want to report - most of the time my gas milage ranges between 18 - 22 mph. This is way below the stats that were given to me when the car was purchased. 3)The phone table does not charge my phone and is a complete fail. 4)The visors are too short and hardly serve a purpose.
NHTSA complaint #11709145 — an unverified report by a vehicle owner.
I am submitting this complaint to document an unresolved vehicle safety concern and loss of confidence in safe operation. My vehicle experienced serious safety-related malfunctions and warnings, and despite service visits, I was not provided written confirmation that the vehicle was safe to operate. After repairs were reportedly completed, I repeatedly requested written safety verification, which was not provided. Due to the unresolved safety concerns and lack of written safety assurance, I did not feel it was safe to resume driving the vehicle. A loaner vehicle was provided while the safety issues were being addressed. The loaner was later recovered before my safety concerns were resolved and without advance notice, leaving me without a vehicle that I could confirm was safe to operate. I am reporting this because I continue to lack confidence in the safety of the vehicle and want this documented as a safety concern. This complaint is not about customer service, but about unresolved safety issues and the absence of written confirmation that the vehicle is safe to drive.
NHTSA complaint #11708815 — an unverified report by a vehicle owner.
This is another complaint with the same issue. Got gas on January 1, 2026, the truck did not how any indication that it was going to have any problems. Engine shut down and wouldn’t turn back on. This has happened twice after getting gas, no dealership knows the problem. This is casing me stress and putting myself and family in danger. Considering it stops out of no where
NHTSA complaint #11708241 — an unverified report by a vehicle owner.
Toyota RAV4 LE gas pump burst and caught fire leading to total fire damage along with major water damage from the firefighters putting out the fire. The vehicle was idle for hours at the time of explosion of the fuel pump. This was a major safety hazard/risk especially being that myself and two others were minutes away from going out to the vehicle before it all happened as I was getting ready to take a friend home for the night. A claim representative will look into this matter in coming days.
NHTSA complaint #11707386 — an unverified report by a vehicle owner.
While traveling back from out of state, the fuel sensor and fuel gauge failed causing me to run out of gas when the fuel gauge stated I had just a tick under a 1/4 tank of gas left and the app read 35 miles left. While driving on freeway at freeway speed, the car sputtered, bogged down and then stalled, placing me in a very dangerous situation broken down on the shoulder of the freeway in the desolate country at night with semi trucks and cars flying by at estimated between 70-80 mph. While stalled and waiting for help, all the lights except the hazard flashers went out. The Sheriff assisted and added 2 gallons of gas that finally got the car restarted and I was able to get to the gas station which was 1 mile ahead of where I had been stranded. I kept filling the gas tank not allowing it to go under 1/2 tank on the fuel gauge the remainder of the trip home. I took the car to Tansky Sawmill Toyota for service, who thought it was a fuel sensor in fuel tank, which had to be dropped, resulting in a tube from the fuel sender being disconnected and not taking fuel from the other side of the tank and corrosion was cleaned out. They had to go through electrical system to check the fuel gauge which had corrosion on the electrical harnesses and sensors not caused by water or rodents - still unknown cause - resulting in $6500.00 to replace both electrical harnesses 82152-0R370 wire FR Door LH and 82141-oRB80 wire Instrument Panel! Known Toyota defect as the 2019 Rav4 Hybrids have already been recalled. Issues of this type with the regular Rav4s are posted all over the online Toyota boards. My platinum extended warranty on my well cared for 2019 RAV4 with 45,131 miles (purchased at 3 year lease end) refused to all of the charges and the dealership did not budge, sticking me with 6 hours of diagnostic fees over what the warranty allowed in the sum of $1014.37. These harnesses need recalled so no one else is stranded in a very dangerous place on the side of the freeway!
NHTSA complaint #11706591 — an unverified report by a vehicle owner.
Strong gas smell when the engine is turned on. I started feel this issue about 2 year ago, now the gas smell is more stronger every time engine is turned on.
NHTSA complaint #11705340 — an unverified report by a vehicle owner.
My 2019 Toyota RAV4 Hybrid (VIN: [XXX] ) suffered sudden engine failure due to coolant intrusion. On Nov 20, 2025, Johnstons Toyota in Harriman, NY (RO#XXX) diagnosed the issue and recorded DTCs P26CA31 and P26CB, which indicate failure of the coolant flow control/bypass valve. The dealer confirmed heavy white smoke from the exhaust with a strong coolant smell and advised the engine had failed, recommending a replacement. This vehicle is part of the early 2019 Japan-built batch widely known for premature electric water pump and coolant-flow system failures. Internal impeller swelling, seal leakage, and bearing seizure can cause coolant pressure spikes and ultimately head-gasket failure with coolant entering the cylinders. This defect has been reported by thousands of RAV4 Hybrid owners (2019–2021). Toyota has addressed it quietly through internal TSBs such as XXX and XXX but no public recall has been issued. The safety risk is severe: the engine began emitting thick white smoke and ran roughly, risking sudden power loss, overheating, or engine seizure while driving. A stall at highway speed could easily cause a collision. Toyota USA opened Case #XXX but declined assistance despite the defect being well documented. This failure was sudden, with no warning lights prior to the incident. Given the widespread nature of this defect and its clear safety implications, I request that NHTSA open a formal investigation into the electric water pump/coolant system failures in 2019–2021 Toyota RAV4 Hybrids and consider requiring a safety recall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11700834 — an unverified report by a vehicle owner.
Stopped for gas on 11/6/2025 immediately after getting gas the truck shook twice, the power steering light and engine shut down light came on and the truck turned off. Waited for a few minutes to turn the engine again it wouldn’t start. Got it towed to my nearest dealership who kept it for a day. Said there was nothing wrong with the truck, there was no code showing and they couldn’t determine the cause of the problem.
NHTSA complaint #11700238 — an unverified report by a vehicle owner.
I stopped for gas; my car would not start. The power steering fluid light came on. I went inside to purchase some but when I returned to the car, there was no place to pour it. After a few minutes the car started. About a month later, my husband stopped for gas and the car killed right after he left the gas station, about 10 minutes later, it started. Took it to a mechanic, they couldn't find anything wrong with it because the check engine light wasn't on and the car wasn't giving any problem codes. About two weeks ago, I stopped for gas, the car wouldn't start. Finally got it started, and the check engine light came on. However, it's still not reading any codes.
NHTSA complaint #11692981 — an unverified report by a vehicle owner.
1. My vehicle had a hybrid warnings and stopped running altogether, but the issue went away after clearing the codes. It came back at 105000mi, Toyota won't help with the $6000 repair. High Voltage Under Floor Cable and Traction Motor Cable on my vehicle (2021 Hybrid Rav4 XLE registered in Massachusetts) is affected by excessive and dangerous corrosion due to a Toyota design issue. 2. The vehicle could suddenly shut off at highway speeds per Matt with Service at Autofair Toyota Tewksbury. Sudden stoppage or deceleration may result in fatal collisions at speed. This failure also leads to fatally high-voltage energizing of the chassis and other frame components in some cases. 3. This is a known design flaw on Toyota hybrid, high-voltage cables/connectors, leading to excessive corrosion and dangerous failure of the hybrid system. There is an extended Toyota customer support program (CSP: 22TE09) valid through 8 years or 100000mi. I purchased the vehicle at 92,000mi but the dealership (CarFive Nashua, NH) and Toyota failed to inform me of this issue (a standard procedure per the CSP) so I could make an informed decision and perform preventative maintenance. Toyota did send me notice of an airbag recall after purchase, so I know they had my information. Now they have left me without options at 105000mi. 4. Yes. It has been inspected and the high voltage cable corrosion confirmed by Autofair Toyota Tewksbury (MA). Image from diagnosis video attached. 5. Warning messages in OBD2 screenshot attached. 6. I'm looking for Toyota to cover the repair for this issue; I've had to repair a valve head gasket and replace the AC system condenser already and this car is barely 4 years old.
NHTSA complaint #11686648 — an unverified report by a vehicle owner.