2019 Toyota RAV4 fuel/propulsion system problems

“While driving in the mountains on a hot day, the car suddenly reported numerous faults, including check engine, parking brake malfunction, pre-collision system malfunction, AWD system malfunction, and secondary collision brake system malfunction. The car lost power and forced us to pull over on the side of a dangerous mountain highway. We powered-off the car for a few minutes and started it again and were able to proceed to our nearby remote mountain destination without another loss of power, but the faults remained. The next day we were able to get the car to a nearby NAPA store to read the check engine codes, which there were only 2 of the "P0087" code. I had them clear the fault codes in order to be able to safely drive the car (~120 miles) back home. Some quick research shows a known issue and TSB for that in our exact high-altitude and high-temperature situation - Toyota T-SB-0058-22, related to a known design flaw with the ECM and fuel suction tube. Luckily, it did not throw the errors again during our drive home. I made an appointment at our local AutoNation Toyota Arapahoe for the following week. I detailed the issue and provided pictures of the errors…”

“Vehicle consistently accepts only approximately 9–10 gallons of fuel when the fuel gauge indicates empty, resulting in significantly reduced driving range. Issue has been widely reported by other Toyota RAV4 Hybrid owners and appears related to fuel tank design. Manufacturer declined assistance and referred responsibility to selling dealer despite known complaints.”

“This is another complaint with the same issue. Got gas on January 1, 2026, the truck did not how any indication that it was going to have any problems. Engine shut down and wouldn’t turn back on. This has happened twice after getting gas, no dealership knows the problem. This is casing me stress and putting myself and family in danger. Considering it stops out of no where”

“Toyota RAV4 LE gas pump burst and caught fire leading to total fire damage along with major water damage from the firefighters putting out the fire. The vehicle was idle for hours at the time of explosion of the fuel pump. This was a major safety hazard/risk especially being that myself and two others were minutes away from going out to the vehicle before it all happened as I was getting ready to take a friend home for the night. A claim representative will look into this matter in coming days.”

“While traveling back from out of state, the fuel sensor and fuel gauge failed causing me to run out of gas when the fuel gauge stated I had just a tick under a 1/4 tank of gas left and the app read 35 miles left. While driving on freeway at freeway speed, the car sputtered, bogged down and then stalled, placing me in a very dangerous situation broken down on the shoulder of the freeway in the desolate country at night with semi trucks and cars flying by at estimated between 70-80 mph. While stalled and waiting for help, all the lights except the hazard flashers went out. The Sheriff assisted and added 2 gallons of gas that finally got the car restarted and I was able to get to the gas station which was 1 mile ahead of where I had been stranded. I kept filling the gas tank not allowing it to go under 1/2 tank on the fuel gauge the remainder of the trip home. I took the car to Tansky Sawmill Toyota for service, who thought it was a fuel sensor in fuel tank, which had to be dropped, resulting in a tube from the fuel sender being disconnected and not taking fuel from the other side of the tank and corrosion was cleaned out. They had to go through electrical system…”

“My 2019 Toyota RAV4 Hybrid (VIN: [XXX] ) suffered sudden engine failure due to coolant intrusion. On Nov 20, 2025, Johnstons Toyota in Harriman, NY (RO#XXX) diagnosed the issue and recorded DTCs P26CA31 and P26CB, which indicate failure of the coolant flow control/bypass valve. The dealer confirmed heavy white smoke from the exhaust with a strong coolant smell and advised the engine had failed, recommending a replacement. This vehicle is part of the early 2019 Japan-built batch widely known for premature electric water pump and coolant-flow system failures. Internal impeller swelling, seal leakage, and bearing seizure can cause coolant pressure spikes and ultimately head-gasket failure with coolant entering the cylinders. This defect has been reported by thousands of RAV4 Hybrid owners (2019–2021). Toyota has addressed it quietly through internal TSBs such as XXX and XXX but no public recall has been issued. The safety risk is severe: the engine began emitting thick white smoke and ran roughly, risking sudden power loss, overheating, or engine seizure while driving. A stall at highway speed could easily cause a collision. Toyota USA opened Case #XXX but…”