Toyota RAV4 Forums banner
Cancel
Create thread New Garage Forums

Issue with fuel tank sensor on 2023 Rav4 Hybrid

Jump to Latest
1 - 20 of 41 Posts
O

OHRav4

· Registered
Joined
·
1 Posts
Discussion starter · #1 ·
We bought a 2023 Rav4 Hybrid in mid January 2023 and last week I filled the tank up for the 3rd time. Each time I filled up the tank it only took about 10.5 gallons of gas, even though the panel said I had 30 to 35 miles left to empty. At the time I filled up last week the car had just slightly under 1200 miles on the odometer so we are getting close to 40 mpg. However, the fuel tank specification is the Rav4 has a 14.5 gallon fuel tank and we are not getting anywhere near that capacity when fueling.

I called the local Toyota dealer that we purchased the car from regarding the discrepancy in the miles to empty, the fuel tank capacity, and the fuel delivered. The service rep gave me a BS story (I think) that there is 2-3 gallons of "spare" capacity in the event that you go beyond the miles to empty estimate. We had a 2011 Highlander with the same capacity fuel tank capacity and when the fuel gauge said I had about 1 gallon left in the fuel tank, that is what I would be able to deliver at the pump. We are currently able to drive about 400 miles before the fuel gauge says we need to fill up but I'd like to be able to extend that to the 525 that the panel says we have when the tank is full without anxiety of running out of fuel.

Before I go to the dealer and demand a warranty claim, I wanted to hear from other newer Rav4 owners if they have similar problems or if their fuel gauges are accurate.

TIA for the feedback.
 
#2 ·
There have been probably 1000+ posts on this subject since 2019. Suggest trying a search.
 
  • Like
Reactions: 462478, Coupeman, kyledamron and 1 other person
Save
Reply Quote Like Like
#3 ·
Dr. Dyno is correct, it has been discussed quite a bit.

The service rep is sort of right. It appears Toyota wanted to introduce a buffer to deter us from running the car dry...LOL. My wife's 2022 Highlander ICE is the same way. Took me a while to trust the gauge but it made understanding what was going on in my RAV4 easier. You get used to it, at least, I did.
 
#4 ·
The advertised size of the tank is dictated by the standards bodies (SAE, NIST). The picture from the standards has been posted dozens of times in the threads you can search for. Toyota cites the usable area (defined by the standards bodies, not a unique to Toyota term) as 9.3 gallons between the needs gas soon type message and the auto shut off. There is supposed to be a buffer both above and below those points, again defined by the standards bodies. These terms aren't new ones, been around for years.

If your needle is resting a needle width beyond the F mark you are what Toyota defines as where you should be at auto shut off.

An article supporting this view is at Fuel Tank Capacity and Gas Pump Accuracy By Juana Williams from NIST.
 
#6 ·
bobcat_mt said:
I’m having this issue, however I have plain evidence that the tank is not filling up completely. This photo was taken right after filling up and the pump clicking off automatically. 2023 Hybrid Limited with 1700 miles on it. View attachment 197867
Click to expand...

Since your historical MPG is input to the range calculation, what MPG were you showing? Did you use the 1 click additional method?
 
#7 ·
We have a Japan built XLE hybrid and am not experiencing that problem. I would guess that any changes made to correct the previous tank filling issues would be implemented identically to every factory and for all models. I'm currently averaging about 43 MPG, and this was after rounding up to the nearest $0.25 after the pump first clicked off at a Costco, after filling it up at the highest flow rate.

Image


Where was your Rav4 built and as @mikefocke asks, what is your current fuel economy?
 
#8 ·
Our 2023 Hybrid Limited was built in Kentucky on May 1st, 2023. I never fill any more than the automatic shutoff or “top off”. Filled up today with about 1/8 tank and it only took about 8.7 gallons. Gauge shows close to full but not all the way. The car gets 42+ MPG in town and around 35 mpg on the interstate (80+ mph). I reset the trip meter so next fill up I can compare the computer calculated MPG to actual.
 
#9 ·
Just filled up and got about 13 gallons into the tank before auto shutoff (last couple gallons are very low flow). Range showed 560 miles. Needle is just over F. Last tank average was 44 miles to the gallon. I think I resolved the tank not filling up. Looks like 13 gallons is the magic number after the display shows low fuel message. Last two were fills were 13 gallons. So maybe 1.5 gallons is the reserve. Makes sense to me.
 
#10 ·
I have a brand new 2023 RAV4 Hybrid XSE. Has around 300 miles on it. I just did my first fill up when it said I had about 30 miles of range left. I filled i tup till the pump clicked off on its own. That was about 10 gallons of gas. When I checked fuel level reading in the car it looked like the pic posted above by @bobcat_mt. It didn't show it as totally full.

My question is... Is it safe to try to put a couple of more gallons in there, or will it overflow??
 
#11 · (Edited)
SuitcaseJohnny said:
I have a brand new 2023 RAV4 Hybrid XSE. Has around 300 miles on it. I just did my first fill up when it said I had about 30 miles of range left. I filled i tup till the pump clicked off on its own. That was about 10 gallons of gas. When I checked fuel level reading in the car it looked like the pic posted above by @bobcat_mt. It didn't show it as totally full.

My question is... Is it safe to try to put a couple of more gallons in there, or will it overflow??
Click to expand...
If you use my method I believe it's 100% safe (just my personal opinion of course). I fill at full flow for the first 8 gallons then stop for like 5-10 seconds and let the fuel settle and remove any air pockets (this part may not actually be necessary but it works so I keep doing it). Then I go really slow for the last few gallons. It never clicks off until the very end. At about the 13 gallon mark I hear that familiar swishing sound of fuel level rising up the tank spout and then it clicks off. This method has worked for me three times in a row now. It never overflows, not a single drop. It used to click off at 9 gallons and the tank didn't read full. That's 4 more gallons I'm getting in the tank. Toyota has issues. Mine is a 2023 LE hybrid with like 3200 miles on it.

Added: What I think is bad is to keep adding fuel at full flow after it shuts off the first time, and to keep adding fuel at full flow causing to click off several times. I think this is what makes it overflow into the charcoal canister which is not good for it. My method doesn't do this. It just clicks off normally one time.
 
#12 ·
JoeRAV4Hybrid_2023 said:
If you use my method I believe it's 100% safe (just my personal opinion of course). I fill at full flow for the first 8 gallons then stop for like 5-10 seconds and let the fuel settle and remove any air pockets (this part may not actually be necessary but it works so I keep doing it). Then I go really slow for the last few gallons. It never clicks off until the very end. At about the 13 gallon mark I hear that familiar swishing sound of fuel level rising up the tank spout and then it clicks off. This method has worked for me three times in a row now. It never overflows, not a single drop. It used to click off at 9 gallons and the tank didn't read full. That's 4 more gallons I'm getting in the tank. Toyota has issues. Mine is a 2023 LE hybrid with like 3200 miles on it.

Added: What I think is bad is to keep adding fuel at full flow after it shuts off the first time, and to keep adding fuel at full flow causing to click off several times. I think this is what makes it overflow into the charcoal canister which is not good for it. My method doesn't do this. It just clicks off normally one time.
Click to expand...
Interesting. I think I'll give it a try! Sounds like it might take some practice! heheh
 
#13 ·
JoeRAV4Hybrid_2023 said:
If you use my method I believe it's 100% safe (just my personal opinion of course). I fill at full flow for the first 8 gallons then stop for like 5-10 seconds and let the fuel settle and remove any air pockets (this part may not actually be necessary but it works so I keep doing it). Then I go really slow for the last few gallons. It never clicks off until the very end. At about the 13 gallon mark I hear that familiar swishing sound of fuel level rising up the tank spout and then it clicks off. This method has worked for me three times in a row now. It never overflows, not a single drop. It used to click off at 9 gallons and the tank didn't read full. That's 4 more gallons I'm getting in the tank. Toyota has issues. Mine is a 2023 LE hybrid with like 3200 miles on it.

Added: What I think is bad is to keep adding fuel at full flow after it shuts off the first time, and to keep adding fuel at full flow causing to click off several times. I think this is what makes it overflow into the charcoal canister which is not good for it. My method doesn't do this. It just clicks off normally one time.
Click to expand...
I’m going to try this method because it sounds like a good solution. I will be contacting the dealer though about this issue. A brand new $40,000+ car should not require this much effort just to fill the gas tank entirely
 
#14 ·
Page 250 of owners manual
â– When refueling Observe the following precautions to prevent fuel overflowing from the fuel tank: â—ŹSecurely insert the fuel nozzle into the fuel filler neck. â—ŹStop filling the tank after the fuel nozzle automatically clicks off. â—ŹDo not top off the fuel tank.
 
#15 ·
I do not have a hybrid however I bought a 2023 Rav4 XLE brand new 6/23. On 6/25 I called the dealer because I already needed to fill the gas tank & it was LEAKING gas under the carriage. They told me I overfilled it. Which was BS. A couple days later the “check fuel cap” light came on. Then a few days later the check engine light came on. The code being read was EVAP LEAK. Took to dealer and again they told me I overfilled it. A week later same thing. Come to find out I had a crack on a corrugated pipe on the fuel tank- they had to replace the whole tank. How dangerous I was driving while dripping gas. My car also never filled to 14.5 only 10-11. A week later it left me on the side of the road for 2 hours. Car shut off while driving 70mph. I was told it was a bad fuel sensor. Something is wrong with these brand new cars. And it’s an even bigger nightmare dealing with Toyota corporate. They are rude and disrespectful. Will not listen. This is a lemon. I’m not the only one. My car was manufactured may 2023 in Canada sold to me with 8 miles on it June 2023
 
#16 ·
I have a feeling of having a lemon car as well. But not as serious as yours. My concern is my fc which is only averaging 33 mpg instead of the promised 40 mpg or at least 36. Mines is a '23 hybrid Ltd Japan made.

Back to the topic. I also experienced the same not filling up to the max. I am afraid of topping off the tank.
 
#18 ·
crisps said:
go drive and run out of gas completely
Click to expand...
I agree but you do know you're triggering all the "burning up the fuel pump" dire warnings because someone remembers hearing about it 30 years ago.
 
Save
Reply Quote Like Like
#20 ·
Yesterday I tried my slow fill method and the pump didn't shut off and I overfilled and spilled a little fuel. Smells like gas in the garage. I am now reconsidering this method. I did hear the swishing sound of the fuel level coming up the neck but the pump never shut off. Kind of sucks because I thought I had this figured out. Was enjoying the 560 mile ranges.
 
1 - 20 of 41 Posts
About this Discussion
40 Replies
20 Participants
Last post:
beesonmichael
Toyota RAV4 Forums
posts
1.1M
members
174K
Since
2004
Rav 4 World is the internet's largest Toyota Rav4 SUV and EV online forum community. Discuss towing, modifications, and more.
Full Forum Listing
Explore Our Forums
4.3 General 4.3 Mechanical 4.5 RAV4 Hybrid (except Prime) 4.5 RAV4 Prime 4.3 Exterior