Toyota RAV4 Gas Tank Not Filling: Causes & How to Fix

If you own a Toyota RAV4 2019 Hybrid, you will have noticed that the gas tank is not filling. You are not alone in this since many owners of this car have the same complaint. This tank was designed to have a 14.5-gallon capacity. However, it only takes about 11 gallons. Because of this issue, this car doesn’t meet up to expectations with respect to fuel economy.

toyota rav4 gas tank not filling

Explaining the “Gas Tank Not Filling” Issue

As expected, the RAV4 2019 Hybrid is an amazing car. Records show that as of 2019, it was Toyota’s top-selling hybrid in the United States. However, different owners complained that the gas tank does not fill up.

What is this issue about? It was reported that most owners could only get about 10 gallons, at most 11 gallons, into their cars. Because of this, people could only travel about 200 miles on a full tank instead of 580 miles. This was mostly because they wanted to avoid all the environmental risks associated with “topping off.”

The question is: What could be the cause of the problem? First of all, if you are facing this issue, there is no need to panic. Toyota automaker has not even been able to figure out the main reason behind the problem.

Experts say the problem is the shape of the gas tank. The advice from Toyota is that owners of the RAV4 can still refuel once they notice the “low fuel light.” However, it is important not to “top off” when refueling due to possible environmental risks.

Toyota RAV4 Gas Tank Not Filling: Fixing the Issue on Your Own

Clearly, so many buyers are frustrated at this problem and would discourage anyone else from getting the car. However, it isn’t such a big deal for some others. Toyota is still investigating this issue and has given interim suggestions which we have stated above.

However, if you are not satisfied with topping off when you get the signal, you should see an accredited auto specialist. You can also visit any Toyota Experience center close to you.

While Toyota is still figuring out this issue and the best solution to the problem, here is a suggestion of our own. We suggest that you try to install a replacement gas tank. The new fuel tank you purchase and install will replace the original one that came with the car.

However, there is no guarantee that the issue wouldn’t reoccur in the nearest future if it is caused by something other than the size and shape of the gas tank. Other than this, there doesn’t seem to a serious problem with the Toyota RAV4 2019/2020 Hybrid.

Toyota’s Latest Solution to the Problem

Last December, Toyota sent letters to owners of its RAV4 2019/2020 Hybrid concerning the gas tank issue. The company explained its measure for dealing with the issue. It stated that owners can enroll in the Customer Support Program to fix the problem at no cost.

The proposed warranty cover is 100,000 miles or 8 years. This way, second-hand owners and other owners that didn’t notice the issue can also partake in the program. To participate in the Customer Support Program, check the steps below:

  • Step 1 – Reach out to your auto dealer via a phone call to report the gas tank problem.
  • Step 2 – Ask your dealer if they are familiar with the current Customer Support Program from Toyota.
  • Step 3 – If they are, then set up an appointment. Ensure that you request a loaner ahead of time.

Step 4 – If they aren’t, then you should contact Toyota directly to request assistance and to be part of the program. What if you have already fixed the issue by replacing your tank? Not a problem, you can still reach out to Toyota for a reimbursement. You should get your money back as long as you have your receipts to prove that you fixed the issue.

Interestingly, Toyota’s fix for this issue has nothing to do with the tank. It replaces three different parts of the car’s fuel delivery system. The good news is that you can complete the fix in one business day.


So your Toyota RAV4 gas tank is not filling up. That is no longer an issue. We have explained the major cause for this and how you can deal with the problem. The good news is that Toyota has set up a Customer Support Program to help RAV4 owners fix this issue.

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