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#21 ·
ronsig said:
I am booked in to get my fix done in early April. I was told I would only get a loner if it takes more than one day. But how will they know that?? If they discover it will be longer and I am at home, will they send me a rental??? Mmmm...
To those who have had it done, how long did it take?? Thanks
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I was advised by my service rep to call Toyota Customer Relations at (800) 331-4331 about getting them to pay for a rental. I bought my 2020 Limited in late February, 2020 and was well aware of the problem. I even talked to my salesman about it. He assured me they were working on a solution and by the late fall they had one. I had to make two trips to the dealer in Reno, NV, which is almost an hour away. The first was to get an official diagnosis that my car had the fuel tank problem and the second to have the repair done.

This dealer does not have loaners, but they do have cheap rentals. I called the number above and was told to submit all the paperwork for the two trips, the rentals and the repair and that they would consider my request. I was forceful in advocating that it was only fair for them to pay for the rental given that I bought the car trusting that they would step up to the plate on the repair.

I submitted the paperwork after the work was done and sure enough, got a check 10 days later, which cost them $89 on a $40k+ Rav4 purchase. I recommend that you do the same thing.
 
#23 ·
Mine went in this morning (2019 Hybrid). This is the SECOND fix for the same problem. Originally there was a problem with the sending unit and that was replaced with a new tank as well. The problem recurred not long afterwards. Hoping this "fix" will work but don't really trust Toyota at this point. They never sent me any letters, etc... even tho the vehicle was fixed under their direction the first time. Had to ferret this all out by myself - Calling or writing to Toyota is a waste of time - they do nothing. Only have 9000 miles on the vehicle. This should not be happening.
 
#24 ·
JimEgan2021 said:
Mine went in this morning (2019 Hybrid). This is the SECOND fix for the same problem. Originally there was a problem with the sending unit and that was replaced with a new tank as well. The problem recurred not long afterwards. Hoping this "fix" will work but don't really trust Toyota at this point. They never sent me any letters, etc... even tho the vehicle was fixed under their direction the first time. Had to ferret this all out by myself - Calling or writing to Toyota is a waste of time - they do nothing. Only have 9000 miles on the vehicle. This should not be happening.
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I'd love to know what the dealer used for the second fix as this is the first I've heard. Was there any reference to any official Toyota wide program or is the dealer just covering up for the fact that their mechanic screwed up the first one. Love to know the part #s used.
 
#25 ·
mikefocke said:
I'd love to know what the dealer used for the second fix as this is the first I've heard. Was there any reference to any official Toyota wide program or is the dealer just covering up for the fact that their mechanic screwed up the first one. Love to know the part #s used.
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Part numbers used for 2nd fix:
04000-15142
04000-15247
04000-16142
Should say that this fix worked for awhile. Lately, I find myself restarting the pump once or twice to get the gauge to read Full or higher. Could be the Texas heat - not consistent, varies by station. BTW, these are the same parts that were replaced during the first fix plus the sending unit. Still awaiting any official notification that my car is included in any vehicle campaign. Toyota USA sucks and blows at the same time if that's possible.
 
#26 ·
Would also say here that many others have this problem with various different cars, not just this one. I've seen other hybrid variants (Avalon, etc...) where people have the same issue. Other brands have experienced this problem as well. Also from my research it is clear that the gas station pump may be part of the problem. While it is supposed to be well regulated in delivering X gas per minute, it doesn't always work that way. Some people use different pumps at the same station or a different station without issue. I should say that I've made my second 3000+ mile trip with this vehicle and the experiences have been different at every gas station I've been to - one station for example, pumped so much gas into the tank that the gauge stayed above full for more than 80 miles. Other stations needed extra pumps to get it to fill - beginning to think that the gas stations are as much of a problem as the car is, especially because you see it in other variants of Toyota hybrids and other brands of cars as well.
 
#27 ·
JimEgan2021 said:
Part numbers used for 2nd fix:
04000-15142
04000-15247
04000-16142
Should say that this fix worked for awhile. Lately, I find myself restarting the pump once or twice to get the gauge to read Full or higher. Could be the Texas heat - not consistent, varies by station. BTW, these are the same parts that were replaced during the first fix plus the sending unit. Still awaiting any official notification that my car is included in any vehicle campaign. Toyota USA sucks and blows at the same time if that's possible.
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Jim Thanks

Same parts as my dealer used in November of 2020.

My car was the first my dealer did. The three parts fix has worked for many fill-ups since with no times that the gauge showed less than full after a max fuel rate fill and I let the nozzle shut itself off. My most used station is a high volume one and may get better maintenance than some others do. Before the fix (after the first few fill ups) I was always less than full on the gauge. Of my 85 fill ups, only two were done by an attendant and both of those were before the fix and were grossly short of the F mark. I rarely get below 1/3 tank before I fill. I haven't filled at 100F after the fix as my typical fill is early in the morning.

The auto shut off is the responsibility of the pump and not the car. That may account for the pump to pump variations you are seeing.
 
#28 ·
I don’t get what is the problem. The pump shutoff is a pure mechanic thing, so unless the fuel tank is causing fuel to reach the top without being full, you should always get a full tank, no? Is it just a matter of the gauge being inaccurate?
 
#29 ·
If one looks at the diameter of the hybrid fuel tank filler, it is smaller than for regular tanks. Pumping a liquid through a narrower pipe at the same pressure, flow rate, would increase the back pressure and click off the pump more quickly. When I use the slower flow rate on pumps that have them, the problem disappears.
 
#30 ·
Mr. Archanfel said:
I don’t get what is the problem. The pump shutoff is a pure mechanic thing, so unless the fuel tank is causing fuel to reach the top without being full, you should always get a full tank, no? Is it just a matter of the gauge being inaccurate?
Click to expand...
www.rav4world.com

Fuel fill issue has a real fix now!

Got a call from a director of my local service department that new parts (fuel tank, fuel sending unit etc...) came in and I can schedule an appointment to replace it. Yes they are the new design parts, not the swap for the old ones. I don't have the car anymore but they had me on file for a...
www.rav4world.com www.rav4world.com

good information in here.
 
#31 ·
JimEgan2021 said:
Part numbers used for 2nd fix: 04000-15142 04000-15247 04000-16142 Should say that this fix worked for awhile. Lately, I find myself restarting the pump once or twice to get the gauge to read Full or higher. Could be the Texas heat - not consistent, varies by station. BTW, these are the same parts that were replaced during the first fix plus the sending unit. Still awaiting any official notification that my car is included in any vehicle campaign. Toyota USA sucks and blows at the same time if that's possible.
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Same problem here - for the second time. The 14.5 gallon tank would only accept 11 gallons from nearly empty. Talked two three dealers; two had no idea what I was talking about and wanted $160 jest to look at the car! The area third dealer was aware of the problem and offered to "fix" it under warranty. Hmmm...two new gas tanks in three years?? The same parts were ordered as replaced the first time. I was concerned that the charcoal canister for the EGR system was clogged or defective from overfilling the tank at a cost of some $1200.00 I don't top off the tank and the dealer didn't mention a potential problem, so I kept my damn mouth shut.! I'll give this dealership a try since it costs me nothing. I was happy with their knowledge but would like to have a full 14.5 gallons when I travel across country on business. 2019 RAV4 hybrid - 74,000 miles. Change oil every 5k miles and keep the hybrid battery pack filters clean. I've have had no other problems. Runs great with great in-town mileage (over 40). On the highway it gets 38 mpg.
 
#32 ·
There have been literally thousands of posts on this 14.5 gallon/600 mile range but only getting in 10-11 gallons "issue." Feel free to either fight it or work with it but the short answer is the 14.5 gallons is really there as shown in post #12 but most people are afraid to actually fill the tank and that's after not using the last few gallons for fear of running out. And with that, I'm out! :p
 
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#33 ·
My 2020 RAV4 hybrid XSE was one of the first ones that got the TSB done at my dealership. I confirmed that they have changed the gas tank by looking underneath the car (it looked brand new). After the refuel warning light comes on (with about 30 miles range left)I am still able to only pump about 9 gallons. After that, I have to slowly pour and additional 4 gallons, sometimes even 5.5 . At this point I am not even sure what is the exact capacity of the tank and i don't think the TSB has improved anything.
 
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