HybridFLfan

2019 RAV4 Hybrid Gas Tank

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I've had my 2019 RAV4 Hybrid for about 5 months and have encountered a major issue with the gas tank capacity.  Shortly after purchasing the new vehicle, I realized that any fill up of the tank was incomplete.  Fuel capacity is 14+ gallons and I'm seldom able to squeeze in 8-9 gallons when nearly empty.  The dealer has replaced the tank, which has not fixed the issue.  Toyota is aware of the problem, but they do not have a solution yet.  Anyone else encountering this issue of having only 2/3 the fuel capacity and thus shorter distances to empty?  Any luck with getting it resolved?

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Just saw a TSB for an issue like this. T-SB-0220-17. Your Rav is not on it, but they may not know all the effected vehicles yet.

If the latch switch gets hit by the nozzle or the splash shield and trips it, an automatic filler vapor block is activated. At that point you can't fill it any more.

The fix is a shield for the switch, but you can experiment to see if that is what is happening.

TSB fuel door MC-10161532-9999.pdf

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  .02    Haven't topped off a gas tank since '80s with Gov't emission standards requiring vapor recovery gas tanks. Only have it a few months but get a full fuel fill pegging the gas gauge every time. Never run a gas tank below 1/8 anyway since the gas is necessary to cool and lubricate the in tank electric fuel pump.

Rav4 '19-20 Hybrids have a plastic "saddlebag" gas tank like those used in many AWD GM SUVs. Unlike a typical saddlebag tank which straddles the driveshaft, these rear electric motor Toys don't use a rear driveshaft, but they do have a metal support beam similarly raising that portion of the bottom of the tank separating the tank into two sections joined at the top, the gas filler being on the forward section and the vapor vent line being on the other. Maybe like the GMs these type tanks have a problem when owners repeatedly attempt to top off the tank forcing liquid gas into the vapor vent line eventually jamming the vapor vent solenoid which is meant to vent vapor, not liquid. Once liquid blocks the vent line the rear section of the tank develops an air embolism and cannot be completely filled.

 

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