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 declined assistance despite the defect being well documented. This failure was sudden, with no warning lights prior to the incident. Given the widespread nature of this defect and its clear safety implications, I request that NHTSA open a formal investigation into the electric water pump/coolant system failures in 2019-?"2021 Toyota RAV4 Hybrids and consider requiring a safety recall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Middletown, NY, USA

Stopped for gas on 11/6/2025 immediately after getting gas the truck shook twice, the power steering light and engine shut down light came on and the truck turned off. Waited for a few minutes to turn the engine again it wouldn-??t start. Got it towed to my nearest dealership who kept it for a day. Said there was nothing wrong with the truck, there was no code showing and they couldn-??t determine the cause of the problem.

- Bartlett, TN, USA

I stopped for gas; my car would not start. The power steering fluid light came on. I went inside to purchase some but when I returned to the car, there was no place to pour it. After a few minutes the car started. About a month later, my husband stopped for gas and the car killed right after he left the gas station, about 10 minutes later, it started. Took it to a mechanic, they couldn't find anything wrong with it because the check engine light wasn't on and the car wasn't giving any problem codes. About two weeks ago, I stopped for gas, the car wouldn't start. Finally got it started, and the check engine light came on. However, it's still not reading any codes.

- Venus, TX, USA

Sudden, unexpected, surprise Surging Idle upon placing the vehicle in Park after driving a 15 minute distance at a top speed of 35mph. Loud Surge up to 2.5 (x1000RPM) Sounds like the Engine Shifted Idle Drops down and immediately begins Surging up again. Idle is high while driving. Some chugging upon acceleration. Immediately drove to Auto Parts store for Diagnostic Test. Started vehicle and showed Technicians what was happening. Diagnostic Test provided: Code P0171 Stored and Permanent System is Too Lean Bank 1 Code P0505 Stored and Pending Idle Control System P117B Stored Fuel Performance/Direct Injector Most Likely Solution: Replace Fuel Pump Primary DTC: System Too Lean Bank 1 Suggested Part: Fuel Pump Operating The Vehicle Could Result in Sudden Shut Down, causing a Collision. Could also Cause Compromised Gas Mileage and Engine Damage. Check Engine Light is On Additional Message states that All Wheel Drive Mode has been disengaged and 2 Wheel Drive Mode is active. No Warning or Any indication that there was any issues prior to the Sudden Idle Surging upon placing the vehicle in Park. I have searched existing recalls for 2019 Toyota Rav-4 and found a Fuel Pump listed. I checked my license plate and VIN only to see the result that there are Zero Unrepaired recalls for both searches. This vehicle is clearly having an internal battle between air and fuel. I find it concerning that 2019-2020 Toyota Rav-4 vehicles had a Fuel Pump recall and yet my search has Provided these results.

- Hammond , IN, USA

Unknown

- Pearl, MS, USA

Dear NHTSA, I am writing to formally lodge a complaint regarding a recurring issue with my 2019 Toyota RAV4, which I believe poses a significant safety concern. The check engine light on my vehicle frequently illuminates, resulting in the disablement of the all-wheel drive (AWD) system. I initially brought my vehicle to a Toyota dealership, where they replaced the charcoal canister (EVAP) three times based on the diagnostic code. Despite these repeated repairs, the problem persists. Suspecting that the issue might be related to the dealership's service, I sought a second opinion from another Toyota dealership. Unfortunately, they provided the same diagnosis and solution, which again failed to resolve the issue. Given that the AWD system is a critical safety feature, especially in adverse driving conditions, I believe this issue should be considered a safety concern and potentially covered by a recall. Further given that the EVAP system is directly tied to the fuel it also should be considered a safety concerns. The repeated failure to address the root cause of the problem not only undermines the reliability of the vehicle but also compromises the safety of its occupants. I kindly request that the NHTSA investigate this matter and consider issuing a recall to address this widespread issue. Your attention to this matter would be greatly appreciated, as it would ensure the safety and satisfaction of Toyota RAV4 owners. Thank you for your time and consideration. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Smithfield , RI, USA

I was told on 6/28/2024 that my car needs a new coolant bypass valve at a cost of $900 on researching this I see there is a class action suit against Toyota because there are so many people with this problem and it should be a recall. Not sure where to go from here.

- Naples, FL, USA

My RAV4 does not hold a full tank of gas. It only allows half a tank get full of gasoline. Toyota says they don't know how to fix, as well as two other shops I have brought it to. There are no engine messages or any other signs of issues. Gas will gush out of the tank when filling up if I do not stop at half way.

- Tampa, FL, USA

"Engine Maintenance Required See Dealer" message keeps appearing on my bashboard took it to my local Toyota dealer and they confirmed the problem is the coolant bypass valve/hose $150 to find the find the problem and $700 to fix apparently this is common in 2019-2022 RAV4s. Now my car won't drive for long without over heating I have only had my car for a year and a half and drive less than 5,000 a year.

- Chicago, IL, USA

Bypass coolant valve is a known issue and while the valve isn-??t broken or leaking the car is prompting for a fix that isn-??t necessary of a fix.

- Orlando, FL, USA

The engine maintenance required turned on at55k miles for the coolant bypass. After trying to get it repaired they had 500 on back order. Thousands of Rav 4-??s are experiencing this with over $800 quote to repair, this cannot just be a basic issue this is bigger.

- National City, CA, USA

The vehicle does not get anywhere near the advertised fuel tank capacity. The fuel tank size IS 14.5, but when fueling it gets >10. Causing the vehicle to get nowhere near the maximum mileage until empty.

- Grand Rapids, MI, USA

Car is shaking when turned on. Will stall if car is not shifted to gear sometimes. When AC is on, car will jump rpm. car acceleration is weak and will jump to 5-6k rpm. car also smells burnt sometimes when driving. car also smells like gasoline sometimes. car does not hold proper amount of gasoline.

- Tucson, AZ, USA

I have 2019 Toyota RAV4. 69,000 miles. I had issue this week when I was driving and park. The gas given by it self after I park the vehicle. and today all of the sudden stop on the road. The dash board shows me EPS light, Battery sign.

- Burtonsville, MD, USA

As I opened up the fuel door - a spring popped out - after I finished fueling- I tried to reopen the fuel door but could not - this can strand a driver when gas gets low as unable to refill the gas tank due to inability to open the door

- Wailuku, HI, USA

The fuel system will not fill up the full tank. When the tank is half full it signals for the pump to stop and that is all that will go in the tank.

- Tampa, FL, USA

Unintended acceleration.

- Rochester Hills , MI, USA

I am not able to fill up the fuel tank to capacity. 8 gallons is all I. An vet in the tank. The tank is not full. The gauges show it-??s about at the half way mark.

- San Marcos , TX, USA

Unknown

- Central Point , OR, USA

The engine on my Rav4 suddenly stopped without any notification while I was driving it on the freeway. I could have been severely injured from the risk of being rear ended by vehicles behind me. I have experienced this twice now, and both times, I have been on a busy highway in the middle of rush hour traffic. While driving, the engine would start sputtering and the vehicle will jolt and shake, eventually causing a warning message to appear that says power steering low, engine shutting off, place vehicle in Park. Then, when I turn the engine off, and try to restart it, it would flash a message that read Not ready to drive. After towing the vehicle to a service department, the vehicle would start up like normal, and the techs could not get vehicle to duplicate the issue. No codes would come up when they place it on a scanner, either. I researched the issue online, and it appears I am not the only one who has experienced this issue with the Rav4. Please reference https://www.rav4world.com/threads/engine-stopped-steering-power-low.323916/ This incident happened twice, once on 3/6 and again on 3/8. I thought the issue was fixed after having my vehicle towed on 3/6 to Freeman Toyota Service where they determined the issue was due to a recall on the fuel pump. However, the incident occurred again on 3/8, and I had to have the vehicle towed as the engine shut off while I was driving on the freeway blocking one lane of traffic on the interchange that connects one freeway to another. I was very fearful of other vehicles crashing into me as some of them were squeezing by between my vehicle and the retaining wall to get around me. It took the wrecker over an hour to get to me due to high traffic time. I have uploaded 2 tow bills I had to pay, and the service invoice for the recall work done. My vehicle is currently at another Toyota Service department where they are telling me they are unable to duplicate the issue.

- Houston, TX, USA