T-SB-0109-20

October 29, 2020

Vehicle Refueling Performance
Service
Category

Engine/Hybrid System

Section

Fuel System

Market USA

Applicability
YEAR(S)

MODEL(S)

2019 - 2020

RAV4 HV

ADDITIONAL INFORMATION

Introduction

Some 2019 – 2020 model year RAV4 Hybrid vehicles may experience one or both of the
following conditions:


The fuel gauge displays less than full when the fuel nozzle automatically clicks off.



The total amount of fuel dispensed while refueling is less than expected when the fuel nozzle
automatically clicks off.

Additionally, the distance to empty mileage displayed on the Multi-Information Display (MID) may
be less than expected. To address these concerns a new fuel tank and fuel sender gauge were
developed. Based on production location and timing, some vehicles may already have the
updated fuel tank and/or fuel sender gauge installed. In cases where these vehicles exhibit this
condition only replace the necessary pre-countermeasure part. Refer to the Production Change
Information section in this bulletin to identify which group the vehicle belongs to and follow the
Repair Procedure in this bulletin to address these conditions.

© 2020 Toyota Motor Sales, USA

Page 1 of 9

T-SB-0109-20

October 29, 2020

Vehicle Refueling Performance
Production Change Information

This bulletin applies to vehicles according to the Production Change Effective information
shown below:


For vehicles produced at TMMC and TMMK plants, replace the fuel tank AND the
fuel sender gauge.



For vehicles produced BEFORE the Production Change Effective VINs
shown below, replace the fuel tank AND the fuel sender gauge.

Table 1.
MODEL

PLANT

PRODUCTION CHANGE EFFECTIVE VIN

Takaoka

JTMDWRFV#LJ042767
JTMEWRFV#LJ043478
JTMRWRFV#LJ042712

Shokki No.1

JTMDWRFV#LD063538
JTMLWRFV#LD063513
JTMMWRFV#LD063544
JTMRWRFV#LD063546

Shokki No.2

JTMDWRFV#LD542643
JTMEWRFV#LD542533
JTMLWRFV#LD541626
JTMMWRFV#LD542518
JTMRWRFV#LD542634

RAV4 HV

© 2020 Toyota Motor Sales, USA

Page 2 of 9

T-SB-0109-20

October 29, 2020

Page 3 of 9

Vehicle Refueling Performance
Production Change Information (continued)

This bulletin applies to vehicles produced BETWEEN the Production Change Effective VINs
shown below:


For vehicles produced BETWEEN the Production Change Effective VIN ranges shown below,
replace the fuel sender gauge ONLY.

Table 2.
MODEL

RAV4 HV

PLANT

PRODUCTION CHANGE EFFECTIVE VIN

Takaoka

JTME6RFV#LJ001004 – JTME6RFV#LJ002042
JTMR6RFV#LJ001026 – JTMR6RFV#LJ002048
JTMD6RFV#LJ001976 – JTMD6RFV#LJ002051
JTMEWRFV#LJ043345 – JTMEWRFV#LJ050080
JTMDWRFV#LJ043912 – JTMDWRFV#LJ050071
JTMRWRFV#LJ045070 – JTMRWRFV#LJ050248

Shokki No. 1

JTMD6RFV#LD001003 – JTMD6RFV#LD004832
JTMM6RFV#LD001004 – JTMM6RFV#LD004805
JTMR6RFV#LD001005 – JTMR6RFV#LD004834
JTML6RFV#LD001069 – JTML6RFV#LD004800
JTMMWRFV#LD063545 – JTMMWRFV#LD073405
JTMRWRFV#LD063550 – JTMRWRFV#LD073417
JTMDWRFV#LD063578 – JTMDWRFV#LD073244
JTMLWRFV#LD063751 – JTMLWRFV#LD073356

Shokki No. 2

JTME6RFV#LD500001 – JTME6RFV#LD502075
JTMD6RFV#LD500003 – JTMD6RFV#LD501845
JTMEWRFV#LD542534 – JTMEWRFV#LD551353
JTMMWRFV#LD542641 – JTMMWRFV#LD551354
JTMDWRFV#LD542646 – JTMDWRFV#LD551352
JTMRWRFV#LD542654 – JTMRWRFV#LD551358
JTMLWRFV#LD542947 – JTMLWRFV#LD551314

Warranty Information
NOTE
Refer to Campaign Publications 20TE04 and 20TE05 for warranty applicability and claim filing instructions.

© 2020 Toyota Motor Sales, USA

T-SB-0109-20

October 29, 2020

Page 4 of 9

Vehicle Refueling Performance
Parts Information
PART NUMBER
PART NAME

QTY

04000-15142

Tank Sub-assy, Fuel SSP Kit

1

04000-16142

Gauge Assy, Fuel Sender

1

Gasket, Fuel Suction Tube Set SSP Kit*

1

PREVIOUS

NEW

77001-0R100
77001-42320
83320-0R050
83320-42100

04000-15247

*The Gasket, Fuel Suction Tube Set SSP Kit includes the fuel suction gasket and two seat cushion hooks.

Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST) & EQUIPMENT

PART NUMBER

QTY

Fuel Sender Lock Nut Wrench Set*

09808-14031-KIT

1

Gas Caddy

1

–

–

Support Columns**
*Essential SST.
**Support Columns are supplied as part of Campaign Publication No. 20TA02 Safety Recall 20TA02
(Remedy Notice): Multiple Models and Model Years; Vehicle May Stall During Driving at Higher Speed
(Technical Instructions).

NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.

REQUIRED EQUIPMENT

SUPPLIER

Techstream ADVI*

PART NUMBER

QTY

TSADVUNIT

Techstream 2.0

TS2UNIT
ADE

1

Techstream Lite

TSLITEPDLR01

Techstream Lite (Green Cable)

TSLP2DLR01

*Essential SST.

NOTE
 Only ONE of the Techstream units listed above is required.
 Software version 15.20.016 or later is required.
 Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.

© 2020 Toyota Motor Sales, USA

T-SB-0109-20

October 29, 2020

Page 5 of 9

Vehicle Refueling Performance
Repair Procedure

1. Confirm the customer refueled the vehicle just before the inspection.

2. Connect the vehicle to Techstream.

3. Using Techstream, check the fuel input reading by using the combination meter data list.
Is the fuel input level less than 12.6 gallons?


YES — Continue to step 4.



NO — Go to step 6.

4. Take the vehicle to a gas station and refuel with the trigger fully depressed until the fuel
nozzle automatically clicks off.

5. Using Techstream, check the fuel input reading by using the combination meter data list.
Is the fuel input level less than 12.6 gallons?


YES — Go to step 9.



NO — Continue to step 6.

6. Does the customer complaint include the refueling amount being less than expected?


YES — Continue to step 7.



NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.

7. Drain 9.8 gallons of fuel into a measurable container using Techstream Fuel Pump Active
Test, which can be found by entering the following menus: Engine – Active Test – Fuel Pump.

© 2020 Toyota Motor Sales, USA

T-SB-0109-20

October 29, 2020

Page 6 of 9

Vehicle Refueling Performance
Repair Procedure (continued)

8. Perform a meter reset and ensure the low fuel light is illuminated.
NOTICE
Ensure the vehicles is on level ground BEFORE performing meter reset.

A. Use the odometer or trip button to change the meter display to odometer.
B. Turn the vehicle OFF.
C. Hold the odometer or trip button and turn the ignition to the IG-ON position
(NOT engine ON).
D. Continue holding the odometer or trip button for approximately five seconds.
The odometer mileage will flash to confirm the reset was successful.
E. Is the low fuel light illuminated?


YES — Continue to step 9.



NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
NOTE
If this bulletin does NOT apply, refuel the vehicle with the drained fuel AFTER the
diagnosis is complete.

9. Based on the Production Change Information section, determine whether the fuel sender
gauge, fuel tank, or fuel sender gauge AND fuel tank need to be replaced.


If the fuel sender gauge needs to be replaced continue to the Fuel Sender Gauge
Replacement subsection.



If the fuel tank needs to be replaced go to the Fuel Tank Replacement subsection.
If the fuel sender gauge AND the fuel tank need to be replaced, continue to the Fuel
Sender Gauge Replacement subsection.

© 2020 Toyota Motor Sales, USA

T-SB-0109-20

October 29, 2020

Page 7 of 9

Vehicle Refueling Performance
Repair Procedure (continued)
Fuel Sender Gauge Replacement

1. Remove the fuel sender gauge.
NOTICE





Do NOT damage the wire harness.
Do NOT damage the cam lock retainers.
When disengaging each wire harness from the clamp, disengage one wire at a time.
Be sure to use the tools outlined for cam lock retainers in Campaign Publication No.
20TA02 Safety Recall 20TA02 (Remedy Notice): Multiple Models and Model Years; Vehicle
May Stall During Driving at Higher Speed (Technical Instructions).

Figure 1.

1
c

4
c

5
c

2
c

3
c

1

Adjuster

4

Claw (Two)

2

Adjuster Plate (Four)

5

Support Column (Two)

3

15-mm Bolt (Four)

Refer to TIS, applicable model and model year Repair Manual:


2019 – 2020 RAV4 HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Sender Gauge Assembly
(W/ Canister Pump Module): Removal”

© 2020 Toyota Motor Sales, USA

T-SB-0109-20

October 29, 2020

Page 8 of 9

Vehicle Refueling Performance
Repair Procedure (continued)
Fuel Sender Gauge Replacement (continued)

2. Install the NEW fuel sender gauge.
NOTICE
 Do NOT damage the wire harness.
 When engaging each wire harness to the clamp, engage one wire at a time.

Refer to TIS, applicable model and model year Repair Manual:
 2019 – 2020 RAV4 HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Sender Gauge Assembly
(W/ Canister Pump Module): Installation”

3. Based on the Production Change Information section, does the fuel tank also need to
be replaced?


YES — Continue to the Fuel Tank Replacement subsection.



NO — The repair is complete, confirm the condition no longer exists.
NOTE
If the fuel tank is NOT being replaced, refuel the vehicle with the drained fuel at this time.

© 2020 Toyota Motor Sales, USA

T-SB-0109-20

October 29, 2020

Page 9 of 9

Vehicle Refueling Performance
Repair Procedure (continued)
Fuel Tank Replacement

1. Remove the fuel tank.
NOTICE
 Do NOT damage the cam lock retainers.
 Be sure to use the tools outlined for cam lock retainers in Campaign Publication No.
20TA02 Safety Recall 20TA02 (Remedy Notice): Multiple Models and Model Years; Vehicle
May Stall During Driving at Higher Speed (Technical Instructions).
Figure 2.

1
c

4
c

5
c

2
c

3
c

1

Adjuster

4

Claw (Two)

2

Adjuster Plate (Four)

5

Support Column (Two)

3

15-mm Bolt (Four)

Refer to TIS, applicable model and model year Repair Manual:


2019 – 2020 RAV4 HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Tank (W/ Canister Pump
Module): Removal ”

2. Install the NEW fuel tank.
Refer to TIS, applicable model and model year Repair Manual:


2019 – 2020 RAV4 HV:
Engine/Hybrid System – Fuel System – “A25A-FXS (Fuel): Fuel Tank (W/ Canister Pump
Module): Installation”

3. Put any drained fuel back into the vehicle and take the vehicle to a gas station to refuel with
the trigger fully depressed until the nozzle automatically clicks off.
4. Confirm the condition no longer exists.

© 2020 Toyota Motor Sales, USA