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Issue with fuel tank sensor on 2023 Rav4 Hybrid

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#21 ·
i just don't get this trying to get every last drop of gas in the fuel tank! Reminds me of Yosemite Sam, "I paid my two bits to see the high divin act and ima gonah see the high divin act"! replaced by "i paid my $35k for a 14 gal. gas tank and ima gona get a 14 gal. gas tank'!
 
#22 ·
RobertB said:
i just don't get this trying to get every last drop of gas in the fuel tank! Reminds me of Yosemite Sam, "I paid my two bits to see the high divin act and ima gonah see the high divin act"! replaced by "i paid my $35k for a 14 gal. gas tank and ima gona get a 14 gal. gas tank'!
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Depending on how long I go between fill ups I have gone up to 771 Kms, 480 miles. I don't feel the need to try to pump a couple of more litres to go another 40 Kms.
 
#23 ·
peterweb said:
Depending on how long I go between fill ups I have gone up to 771 Kms, 480 miles. I don't feel the need to try to pump a couple of more litres to go another 40 Kms.
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If you don't have a hybrid, you need the extra gallon or two, it keeps you from filling up twice a week.
I don't think it is a disease, it is just frustrating, and people are worried something is wrong.
I read this from both sides of the coin. It can sound a bit obsessed..!
 
#24 ·
If you go to the gas station and the pump consistently shuts off with the tank reading 1/8 less than full, that tends to make most people think there's a problem. I've never in my life had a car that did that. Especially not a brand new one. Who wants to stop more often for gas when you bought a hybrid? Who wants a defective car that paid this much money for? o_O
 
#25 ·
JoeRAV4Hybrid_2023 said:
If you go to the gas station and the pump consistently shuts off with the tank reading 1/8 less than full, that tends to make most people think there's a problem. I've never in my life had a car that did that. Especially not a brand new one. Who wants to stop more often for gas when you bought a hybrid? Who wants a defective car that paid this much money for? o_O
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And if that happens at several pumps the sensor reading is clearly defective and they should fix it. (OTOH, how many times in your life did you buy a car that didn't have at least one defect? With the complexity of today's cars, I'm amazed we don't have more problems.)

What has the dealer said, what evidence have you provided (aren't smart phones handy) to force them to open a case with Toyota.
 
#26 ·
OHRav4 said:
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.
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Did they ever figure it out? I am having the same problem since I bought the car new in June. Only 10 gallons with 11 miles to go until empty. They keep giving me the run around and my driving style… I do mainly city driving with 6-15 miles a day.
 
#27 ·
Yes please post results. I didn't even bother perusing it since my dealer salesman told me his service department hasn't seen the issue on newer hybrids (2019-2023). Not in the mood to waste my time on it. I just nurse the last few gallons in. Luckily I only fill up twice a month so it's not so bad. Oh wait, now 2.5 times since it's winter. :cautious:
 
#28 ·
I have the exact same issue. My dealer told me you have to slowly pump your gas, and when it clicks the first time, you have to wait a minute for the bubbles to settle then pump more. I was able to get 13 gallons before overflowing my car. I used to be only get 10 before a car overflowed, and this is when I had 7 miles to empty. The new gas pumping situation with this car is ridiculous. I battled my dealer from June to October about this issue before they took me serious, it turns out it’s still my fault and I don’t know how to pump gas. it’s funny how we pay so much money for this SUV and it takes us so much work just to fill it up.
 
#29 ·
staceyc said:
I have the exact same issue. My dealer told me you have to slowly pump your gas, and when it clicks the first time, you have to wait a minute for the bubbles to settle then pump more. I was able to get 13 gallons before overflowing my car. I used to be only get 10 before a car overflowed, and this is when I had 7 miles to empty. The new gas pumping situation with this car is ridiculous. I battled my dealer from June to October about this issue before they took me serious, it turns out it’s still my fault and I don’t know how to pump gas. it’s funny how we pay so much money for this SUV and it takes us so much work just to fill it up.
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The usable area of the fuel tank is only 9.8 gallons according to an official Toyota CSP mailing. The 14.5 gallons advertised volume is what is permitted by standards bodies NIST and SAE. The points within the tank that should trigger such events as warnings of low fuel, empty and auto shutoff are also defined by those standards bodies.

What happened to the 14.5 minus 9.8 you ask. There is a splash area above the auto shut off point that is designed to prevent fueling overfill that would damage sensors and evaporation hardware. There is an area below the usable area that is a true reserve.

Trying to fill the amount you cite is asking for trouble that is not covered by any warranty. Stop and refill when the Empty alert shows. Fill to the auto shut off point at any speed. Pause a few seconds, And maybe pump to another auto shut off at a slow setting. That should get your gauge needle just beyond the F mark on the gauge.
 
#30 ·
JoeRAV4Hybrid_2023 said:
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.
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I also do the slow fill after it stops at around 11 gallons. I l watch until I see the gas hitting the end of the nozzle. I can usually get another three gallons in this way. I haven't had any gas leak out so far. My Rav4 is almost two years old and I have been using this method the whole time. I generally get around 480-500 miles to a tank with the most being 560. Otherwise my range is about 400 miles. Somehow I got 15.1 gallons in it today. Not sure how that's possible.
 
#31 ·
I had the recall for the fuel tank and sensor level done in 2021 on my 2020 RAV4 XSE. Before the recall I could pump only about 8 gal after the refuel reminder was showing up on the dashboard.
After they replaced the fuel tank and sensor I can pump 9 gal (until the first click on the pump). After that I have to slowly pour anither 4 gallons.
What a joke.
 
#32 ·
OHRav4 said:
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.
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You have about a 3 gal hidden reserve. When your dash says 0 miles left you have about 120 till you get a display saying to shutdown within 6.2 miles
 
#33 ·
relumalutan said:
I had the recall for the fuel tank and sensor level done in 2021 on my 2020 RAV4 XSE. Before the recall I could pump only about 8 gal after the refuel reminder was showing up on the dashboard.
After they replaced the fuel tank and sensor I can pump 9 gal (until the first click on the pump). After that I have to slowly pour anither 4 gallons.
What a joke.
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This is why I don't want my dealer to fix it. Waste of time and they might damage something else while in their possession. It's happened to me before.
 
#34 ·
OHRav4 said:
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.
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The simple fix to this, fill your tank at the slowest speed the pump will go. That means you have to use your hand to hold the trigger as the first clip to hold the pump on is too fast still.

You can do that, or what I do, I fill the tank as full speed, then when it clicks off for the first time, I then hold it at the slowest speed for the last ~2 gallons.
 
#35 ·
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.
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Interesting, I just made a post about this. Makes perfect sense. If you fill really slow you can get 12 or 13 gallons in it....before the pump shuts off.
It will be interesting to see what my mpg is on my current tank..
 
#36 ·
RobertB said:
i just don't get this trying to get every last drop of gas in the fuel tank! Reminds me of Yosemite Sam, "I paid my two bits to see the high divin act and ima gonah see the high divin act"! replaced by "i paid my $35k for a 14 gal. gas tank and ima gona get a 14 gal. gas tank'!
Click to expand...
Not really the point. The gas tank should be able to take 12 gallons with no problem people are getting 10 or 11 . I've never gotten more than 10 in mine until today , got 12 because the pump I always use was running real slow.
 
#37 ·
14.1 gallons after running 124 miles past 0. display read fill up within 10 km or 6.2 miles or engine will stop. switched to EV and went to fill up.
I have filled 14 gal. a few times now and used it as a test to see how far in an emergincy it would go. i am comfortable at 100 miles past 0 if on a trip with Ev to spare driving slow. typically fill up around 12.5 gal.
 
#39 ·
462478 said:
then when it clicks off for the first time, I then hold it at the slowest speed for the last ~2 gallons.
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Hi Guys, based on my research, overfilling our gas tank by 1 to 2 gallons after the auto-click, will it potentially damage our evaporative emissions control (EVAP) system, charcoal canister, purge valve or solenoid if we do this overfilling often?
 
#40 ·
MikeJones2509 said:
Not really the point. The gas tank should be able to take 12 gallons with no problem people are getting 10 or 11 . I've never gotten more than 10 in mine until today , got 12 because the pump I always use was running real slow.
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It is really the point! Some owners are assuming they should be able to stuff 13+ gallons in the rav4s tank when the low fuel comes on or DTE reads 0 and will defeat the high fuel cutoff even though it is clearly stated in owners manual with warnings not to and also tank configurations have been explained in detail many times on this forum to no avail. In a perfect world where gas gauges are 100% accurate, gas pump fueling bases are level and gas pump delivery flow is sufficient to activate auto shutoff, then all would be tickety boo, but this isn't the case. All we have is the auto shutoff.
 
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