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I took my new(as of April 2008) Rav4 Sport into the local dealer for the 15,000 mile checkup. According to the toyota manual its an oil change, tire rotation and retorque the 4WD screw. I picked it up from the dealer, drove it about 65 miles back home and let it sit in the driveway for a day. When I got in it this morning,
the Check engine light, the VSC, and 4WD light came on(solid). I loosened and retightened the gas cap, no change. I saw a previous post about a mouse nest in the engine, but I live in NY and its been mid 30-40's the last few days. Not really
mouse weather. I plan on taking it to a dealer ASAP tomorrow, but any light anyone can shed on this would be greatly appreciated.

Thanks for your time and insight.
 

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They probably knocked loose a vacuum hose on the intake tract somewhere when checking or replacing the air filter. Every idiot oil change shop I take our Highlander to manages to knock this hose loose, even Toyota dealerships. It gives some EVAP check engine light code, but then it also disables VSC & TRAC (& 4WD I guess on the RAV) since that stuff could stall the engine if it's not running light. I have an OBD-2 scanner and just reset the code myself and fix the vacuum hose on our Highlander, although I think the RAV is running a CAN bus system now so if I get a code on the RAV I'll be outta luck unless I buy some new gear (or take it in)
 

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steVTEC,

Thanks for the insight. I called a dealer in another state, and the service guy suggested it might be the air filter hose not being connected. I checked and the
hose seemed to be on ok, and the box lid was tight. Its entirely possible I might be looking at the wrong thing, but I checked anyway. Is the intake hose something I could reach from the top of the engine or something I'd need to look at from the bottom?

Thanks again!
 

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So I went to the dealer today, the same dealer where I brought my car
for the 15,000 mile maintenance checkup. They took it in, and came back
with a diagnosis of a "damaged charcoal filter". They also came back with
a repair cost of $994.00! I explained to them that the car was in perfect working order when I brought it in and I don't live on the side of a mountain, so there was
no way I could have damaged that filter merely driving home. To make a long
story short, the dealer, out of the kindness of their pocket, decided to replace the
filter at no cost to me. As I was checking out, I asked where the filter was located
and was told its between the drivers side front tire and rear...and it's PROTECTED
by a metal cage!!! When I got home I looked underneath the car and saw that they replaced the filter and the metal cage protecting the filter. So I believe that when they went to put the car on the lift, some clown wasn't paying attention and
mushed my filter. Just an FYI for everyone. I'm bitter, very bitter, but happy to have my car back and working!
 

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ah yes, the good ol cannister charcoal filter. :lol: I retrofitted a very nicely designed metal shield piece by mcvite70 here to protect mine. 07's and earlier didn't have this and a lot of people had issues just from standard road water spray hitting the thing. Somebody did probably bang the thing, but it's definitely not a good idea to top off the tank on this car. Apparently that can cause it to fail too.
 
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Funny I came across this.... My '06 RAV (32k miles) just had this issue. Check Engine - VSC - 4WD lights came on. Brought it to dealer and they said it needed a new charcoal filter and some vacuum something or other.... They blamed operator/owner error, they said we must be pulling the the gas nossil out too quickly when pumping gas. This I guess causes gas to leak down some tube and ruin the filter and vacuum thingy...

Tech said since Toyota cannot prove its owner error they will fix under warranty. I'm far from being an expert (can't you tell from my awesome wording in this post), but this sounds like TERRIBLE design to me. I never attempt to overfill my tank, but to wait 10 seconds AFTER pumping to pull the nossil, never heard of that. Now it was me worried, this would have been a $600 job if not under warranty. Does the above diagnositc sound correct??
 

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I am having this problem now with 38K miles. Parts and labor is $2,000. I asked why so much, he stated they also need to reprogram the ECU. Anyone else having to pay this much?
 

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sko580 said:
I am having this problem now with 38K miles. Parts and labor is $2,000. I asked why so much, he stated they also need to reprogram the ECU. Anyone else having to pay this much?

That seems crazy. When I had this issue (the first time) I first noticed the issue when trying to merge onto the highway. While merging onto the highway I lost all power for about 10 seconds and the VSC, Check Engine, 4wd lights were all lit solid. I regained power and carried on. All lights remained lit till I took it into the dealer the next day. They called me and told me that a sensor needed to be replaced (Mass Air Flow Sensor). They replaced the sensor and all was well.

I had those same lights come on again a few months later and took it back. The dealer replaced the sensor again stating that the sensor was soaked in water. I think that the original tech was a bone head and didn't re-install correctly and left the sensor in a place where it was exposed to water.

regardless... I think you may be getting hosed
 

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I didn't have any acceleration issues or stalls from the RAV4. But I have returned from Toyota Service and this is what the report states:

Error Code: P2401, P2402, and P2419

Replaced: Charcoal Cannister, filter and clip. Reprogrammed ECU as per TSB.

I spoke with the tech who serviced my car. He stated this is a common problem. It was common enough that Toyota made a shield for it, which was added to my car after the charcoal cannister replacement to prevent further damage.

As far he could tell, the pump attached to the charcoal cannister went bad. He doesn't know if the motor went bad or whether a loose particle from the filter got stuck in it. He also states they don't provide a replacement for the motor only, it comes as a whole set.

So that's my experience. I hope many will not have this experience.
 

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I now have this problem with my 08 V6 Limited. Check engine light on, VSC & 4wd now disabled. Dealer tells me it is the canister, and they want over $1k to replace. Also tells me were unable to reset it, so now Im driving without 4wd capablility and VSC. Only 42000km on this turd. The 3yr comprehensive warranty expired x 2months ago. I bought this thing last month.

The canister on my G/Fs 06 Matrix went at 50,000km to the tune of $800.

Going to phone Toyota Canada and ask them specifically how long these things are supposed to last. Of course my question is rhetorical - they last just long enough to see the warranty expire

I'm getting this thing fixed, then sold, and then buying anything other than this grossly overrated company can make
 

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I've read this thread, and a number of others relating to the charcoal canister and I have a question or two:

I'm confused as to whether this issue affect all years of RAV or only '06 and earlier?

Does this issue affect both the I4 and the V6?

My understanding is that the '07s and newer have the metal shield...but they're still susceptible to over-filling the tank?

My sister's '08 only has about 17,000 miles but comes off warranty later this year so I want to be prepared.
 

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The lights are apparently no more that "idiot" lights or rush-to-the-dealer lights.
They could mean so many different things you have no clue until you read the codes.

One thing I do know, leaving the gas cap loose for 2 1/2 weeks doesn't set any. :roll:
 

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linuxos77 said:
Funny I came across this.... My '06 RAV (32k miles) just had this issue. Check Engine - VSC - 4WD lights came on. Brought it to dealer and they said it needed a new charcoal filter and some vacuum something or other.... They blamed operator/owner error, they said we must be pulling the the gas nossil out too quickly when pumping gas. This I guess causes gas to leak down some tube and ruin the filter and vacuum thingy...

Tech said since Toyota cannot prove its owner error they will fix under warranty. I'm far from being an expert (can't you tell from my awesome wording in this post), but this sounds like TERRIBLE design to me. I never attempt to overfill my tank, but to wait 10 seconds AFTER pumping to pull the nossil, never heard of that. Now it was me worried, this would have been a $600 job if not under warranty. Does the above diagnositc sound correct??
What I do is to stop trying to put more fuel in the tank as soon as the fuel nozzle safety-stop kicks back. But filling the tank fully should not be a problem as long as you stop fueling when the nozzle stops the first time. I had to do that with the 2009 Forester I had last year, since trying to add more fuel to the tank once the nozzle has stopped makes the fuel gage malfunction (the fuel gage won't show the correct amount of fuel in the tank).
 

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Dr. Dyno said:
The lights are apparently no more that "idiot" lights or rush-to-the-dealer lights.
They could mean so many different things you have no clue until you read the codes.

One thing I do know, leaving the gas cap loose for 2 1/2 weeks doesn't set any. :roll:
My wife's Rav 4 haven't had this problem (the three warning lights ON), since the gas cap was replaced with a new one. Also, since the cap was replaced we have decided not to let the fuel nozzle (at the gas station) overfill the tank. Once it "clicks" off one time, we stop there.

And it makes no sense whatsoever to let the nozzle click more than once, since the tank is already filled hight enough for the gage to point slightly above the full mark.
 

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RayinAlaska said:
And it makes no sense whatsoever to let the nozzle click more than once, since the tank is already filled high enough for the gauge to point slightly above the full mark.
Well, I do exactly the opposite. (You might have guessed that's not unusual for me.) Tanks are built with an expansion dome in the top and are vented a little below it. By letting the venting settle and re-clicking the nozzle several times one can get nearly an extra gallon in after the first click-off. I do it because my wife gets gas points from the grocery store so the more I put in the longer it is between re-fills and the more points we accumulate. I take 25-30 gallons of empty gas cans too. I usually get about 50 cents off per gallon.
On the diesel pickups there's a mod involving shorting the internal vent pipe that both gets an extra two gallons in and avoids a lot of the foaming and bubbling usually associated with diesel fuel.
 

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Dr. Dyno said:
RayinAlaska said:
And it makes no sense whatsoever to let the nozzle click more than once, since the tank is already filled high enough for the gauge to point slightly above the full mark.
Well, I do exactly the opposite. (You might have guessed that's not unusual for me.) Tanks are built with an expansion dome in the top and are vented a little below it. By letting the venting settle and re-clicking the nozzle several times one can get nearly an extra gallon in after the first click-off. I do it because my wife gets gas points from the grocery store so the more I put in the longer it is between re-fills and the more points we accumulate. I take 25-30 gallons of empty gas cans too. I usually get about 50 cents off per gallon.
On the diesel pickups there's a mod involving shorting the internal vent pipe that both gets an extra two gallons in and avoids a lot of the foaming and bubbling usually associated with diesel fuel.
You are probably correct about the Rav 4 (I don't really know). But it's a problem if you do it to a 2009 Subaru Forester, and there is a note about it on the owner's manual. I missed the note and let the nozzle click several times when filling the tank for the first time (new Forester), and from that moment on the fuel gauge would show a little over 3/4 on a full tank. I called the shop about this problem and they told me not to let the nozzle click more than once gains, and that if the problem continued to bring the car in. On the third tank full, the gauge returned to normal.
 

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RayinAlaska said:
But it's a problem if you do it to a 2009 Subaru Forester . . . I let the nozzle click several times when filling the tank for the first time, and from that moment on the fuel gauge would show a little over 3/4 on a full tank. On the third tank full, the gauge returned to normal.
Wow, my '01 Forester never treated me that bad. But I guess it's like a lot of things these days - you buy them and then have to modify them to make them useful.

Back in the 70s I owned a bunch of Fiat 128s. They were great little cars as long as you kept timing belts fresh but they only had about a 9 gallon tank. So what I'd do was modify the vapor recovery canister to allow topping off the tank right up the filler pipe within an inch of the cap. The canister was mounted in the trunk next to the filler pipe. I added a fitting to one and T-ed it into the vent pipe. Transferring it to the next Fiat was a ten minute job but it allowed an extra gallon, 10% more, every trip to the station over the border in RI. The five mile trip home always used enough gas that expansion loss was never an issue.

Today's cars have so many electronic nannys it isn't worth the bypasses you 'd have to invent to do the same thing. Fortunately tanks are a lot bigger. Can't come close with the RAV, but since it has the same tank as the non-hybrids, on a recent trip I got 575 miles on a tank with the Accord.
 
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