About this problem
Some owners find the pump keeps clicking off long before the tank is full, so the car holds far less fuel than it should and the range drops. The cause is usually the tank's vent system or the shape of the tank itself: air cannot escape fast enough, so the nozzle senses the tank is full. It does not damage the engine, but it is a real nuisance.
Across all owner complaints filed about the Toyota RAV4 since 2012, 66 (1.4%) describe fuel tank will not fill all the way, the second most reported problem we track on the RAV4. The reports cluster on the 2019, 2020 and 2021 model years, and the 2019 drew the most, with 49. No recall covers it, so repairs are usually paid by the owner once the warranty ends.
What owners report
Owners of the 2019 and 2020 RAV4, and especially the hybrid, report that the fuel pump clicks off early and the tank will not take a full fill. Some say they can only add 9 to 11 gallons into a tank rated for about 14.5, which cuts the range they expected. The problem is linked to the shape of the fuel tank, not to the pump at the station.
How it gets fixed
Toyota issued a fix for affected vehicles that involves replacing the fuel tank, and some owners report the problem is solved afterwards. Ask a Toyota dealer to check the VIN.
Typical cost: The repair is covered for affected vehicles. Out of warranty a fuel tank replacement costs $1,000 to $2,000.
Complaints by model year
In owners' words
"Fuel tank will not fill completely. When fueling, the pump consistently shuts off before tank indicator reaches "full". Toyota is aware of this issue but refuses to fix my vehicle despite the customer support program notification which is currently occurring."
2019 Toyota RAV4, 300 miles
"Vehicle gas tank will not fill to capacity.. I am stoping at gas stations all the time because I am flying through gas ..and it's a hybrid ..won't fill more than 9 or 10 gals .."
2020 Toyota RAV4, 23,350 miles
Excerpts from public owner complaints filed with the National Highway Traffic Safety Administration, lightly trimmed.
Before you buy a RAV4
- Fill the tank from near empty and compare the gallons with the tank size.
- Ask whether the fuel tank repair was done.
- Check by VIN for open campaigns.
Questions
Which Toyota RAV4 years have fuel tank will not fill all the way?
Complaints are highest for the 2019, 2020, 2021 model years. The 2019 drew the most, with 49 reports.
How much does it cost to fix?
The repair is covered for affected vehicles. Out of warranty a fuel tank replacement costs $1,000 to $2,000.