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If you define the fuel fix issue as ....
  • Does the needle go to or a needle width above the F mark at the first auto-pump-shut-off? Yes. It didn't before the fix.
  • Does the car make the advertised 14.5 gallons of fuel available? Not exactly. There is 9.8 gallons of usable fuel between the reserve point and the auto-shut off point. Don't fill beyond that point. Fill into that splash area and you risk damage to the evaporation control system which fix will be at your expense.
  • Can you use some of the reserve 2.2 gallons in an emergency? Yes but don't go to true tank empty or you'll need a tow truck. The E mark is about at the top of the reserve.
  • Is the 14.5 false advertising? No. All the standards bodies allow the manufacturers to advertise the tank capacity that way and all manufacturers do it.
 
The new parts are used in all 2022 builds. Is it possible that some are no
Nope, this issue is experienced by me in my 2022 RAV4 PRIME xse. The dealership beats around the bush and gives hollow irrational explanations.
t installed correctly? Of course. But it certainly hasn't been an often reported issue here.

Exactly what do you describe as your issue that would cause you to think "this issue" is one you are experiencing.
 
The new parts are used in all 2022 builds. Is it possible that some are no

t installed correctly? Of course. But it certainly hasn't been an often reported issue here.

Exactly what do you describe as your issue that would cause you to think "this issue" is one you are experiencing.
Let me attempt again to explain.
The advertisied fuel tank capacity is 14.5 gallons for 2022 RAV4 xse whereas I went to fuel in when empty sign popped up, and the tank could take only 10.5 gallons of gas. I did the above iteration 4 times. Each time it s the same outcome.
 
Let me attempt again to explain.
The advertisied fuel tank capacity is 14.5 gallons for 2022 RAV4 xse whereas I went to fuel in when empty sign popped up, and the tank could take only 10.5 gallons of gas. I did the above iteration 4 times. Each time it s the same outcome.

There is at the top of the tank going down towards the bottom:
  • A splash area designed to prevent gas from backing up during fill or a hard turn into the evaporation control system (for which you will pay if it gets damaged)
  • An auto shut off the pump point
  • A usable fuel area of 9.8 gallons which includes a point at which a low fuel warning is designed to occur and a Empty display (E) is designed to occur.
  • A reserve below that which is there to allow you to not run out of gas because you will have responded to one of the two warnings. Truly run out of gas and you call a flatbed or have an OBC reader and app and now how to reset the ECU. No longer can you just add a can of gas from your emergency service. And if it has to get "towed" to a dealer, you pay to have the ECU reset.

This multiple areas is what the standards bodies describe as the way that manufacturers are supposed to make all fuel tanks work (think car rentals). You have an advertised 14.5 gallon gas tank because that is the way car makers are told they can advertise. From a practical sense, more like 10 gallons (auto shut off to E).
 
Interesting! Could you please validate if all 2022 RAV4 Xse tanks can take no more than 9.8 gallons of gas?
Also, are you an authorized Toyota rep?
I am an owner of a '19, no connection to Toyota other than I have owned several. This from A5 in an official Toyota CSP 20TE04 to owners. I have posted elsewhere on this forum the diagram from the Society of Automotive engineers detailing how gas tanks are supposed to work, and read the NIST document that is in agreement.

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This from the SAE;

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If you'd like more opinions, use the search function and look for fuel fill. There are thousands of postings on the subject.
 
About 1600 miles on our 02/22 build, and 2 fill-ups either just as the light came on, or just about to come on, and it took between 12.1 and 12.3 gallons each time.
Always filling up with the auto shutoff on pump handle at the lowest/slowest setting.
I am not sure if this is normal, but most of my other vehicles generally have about 2 gallons still in the tank when the light comes on, so with a 14.5 gallon tank, it looks about right.
I wanted to see what the "real" range is when the light comes on, so told her she could safely go 50-75 miles when the light came on.
 
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My experience was quite simple .. first 4000 miles every fill up resulted in the needled going to the full mark after the standard first click shut off. DTE was respectable.
From 4000 miles to 6000 miles, 4 out of 7 fill ups the gauge did not hit the full mark and my DTE was reduced considerably. even after several extra "clicks"
Visit to Toyota and they confirmed my suspicions. After the fix all is (was) well ... (caveat, I have a small hiccup as described in another fuel fill related post that has yet to be cleared up)
 
I'm wondering if anyone is able to confirm if the fuel tank/sensor issue has been fixed in 2022 production model hybrids?
I bought a 2022 RAV 4 Hybrid, a few weeks ago and soon I realized that mine doesn't read correctly. The first time I had to drive long distances in severe weather, although the tank said 3/4 full, it took 9 gallons of gas....more than half the capacity (14.5 gals) of a full tank. not just a quarter tank as the reading said. Then the second time it said there was only 1/4 tank remaining, so I pumped again. The second time I could pump only 4 gallons and the tank was full. So NO, I don't think they have fixed anything. Mine came out of the factory very recently.
 
I have a July 2022 built XSE that has taken over 10 gallons on 2 occasions, otherwise it's 7 to 8 gallons when I top off (6 gas trips however the last was 4 gallons before a trip). I don't want until 1/4 or less to refill, hence the smaller gallons.

The first time was 10.5 gallons and the needle was ever so slightly showing I had more than 1/4 tank remaining. Half of the needle was touching the 1/4 mark (the 2nd half hadn't yet reached the 1/4 mark).
The 2nd time the needle was centered between the 1/4 mark and the small tick below 1/4 remaining and it took 10.4.

There are some variances in use it seems. My hand calculations are between 2 and 4 MPG different than the computer.
Take for instance the 10.5 gallons with over 1/4 tank by needle position vs 10.4 and being 2 needle widths lower on the gauge.
I'm fairly consistent with how I fill but it's not wrong to think I've over/under filled by a quart in either case. A quart of fuel is quite a bit in terms of full or not full based on range. Traveling 350 miles in a single drive with one quart different of fuel is enough to affect the math.
Whatever it is though, I'm positive I can use more than 12 gallons before I get too near the E mark.
I am one tick mark away from hitting the 1/4 mark right now from a ~300 mile trip yesterday. I'll gas up this week and expect it to be less than 10.7 gallons.

I wasn't too aware of the previous concerns (I've read some of the threads months ago when I got the car) but with a few 10 gallon fill-ups with 1/4 tank remaining, the math works out pretty closely to having 14 gallons -unless the miles for the last 1/4 tank is greatly different than any of the other 1/4 tank intervals.
I won't be testing. I'm just home from a trip and want to top off before spending a week running errands to sample the last 1/4 tank.
 
weird, May 2022 hybrid, fill with gas to first click...needle always a hair above full mark
have been using a total of 7 different pumps in three states, all behave the same
never been boned by the 'gas tank filling issue'

fill to first click, amount pumped feels correct, get back in car, needle above full

so, for me, my specific situation, no problems seen

further details. Mobil stations or Irving stations.
OPW and Husky pump handles, none are vapor recovery style

I never fill past first click on the rav, though I sometimes top off tacoma, 4runner, and Yaris
with this rav4 and even more complex gas vapor emissions tech, not going past first click on the rav
 
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