NHTSA ID Number: 11005139
Manufacturer Communication Number: T-SB-0042-24
TSB/Document Date: 2024-07-23
Summary
Some 2023 model year RAV4 Hybrid
vehicles may exhibit a condition where the fuel gauge reads between 3/4 to 7/8 full after fully refueling. No Diagnostic Trouble Codes (DTCs) are associated with this condition. Follow the Repair Procedure in this bulletin to address this condition.
T-SB-0042-24
May 1, 2024
Fuel Gauge Does Not Read Full After Refueling
Service
Category
Engine/Hybrid System
Market USA and
Section
Mexico
Fuel System
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2023
RAV4 HV
WMI(s): 4T3
Introduction
Some 2023 model year RAV4 Hybrid vehicles may exhibit a condition where the fuel gauge reads
between 3/4 to 7/8 full after fully refueling. No Diagnostic Trouble Codes (DTCs) are associated
with this condition. Follow the Repair Procedure in this bulletin to address this condition.
Table of Contents
Production Change Information ...............................................................................................2
Warranty Information ...............................................................................................................3
For USA Market..................................................................................................................3
For Mexico Market ..............................................................................................................3
Parts Information .....................................................................................................................3
Required Tools & Equipment ...................................................................................................4
Repair Procedure.....................................................................................................................4
© 2024 Toyota Motor Sales, USA
Page 1 of 5
T-SB-0042-24
May 1, 2024
Fuel Gauge Does Not Read Full After Refueling
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
PRODUCTION CHANGE EFFECTIVE VIN
4T3DWRFV#RU134790
4T3RWRFV#RU134790
4T3BWRFV#RU134790
4T3MWRFV#RU134790
RAV4 HV
TMMK
A25A-FXS
4T3LWRFV#RU134790
4T3D6RFV#RU152241
4T3B6RFV#RU152241
4T3E6RFV#RU152241
4T3T6RFV#RU152241
© 2024 Toyota Motor Sales, USA
Page 2 of 5
T-SB-0042-24
May 1, 2024
Page 3 of 5
Fuel Gauge Does Not Read Full After Refueling
Warranty Information
For USA Market
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG2407
R & R Fuel Tank Assy
2.0
77001-0R###*
87
13
*Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired
by searching for the parts in the Electronic Parts Catalog using the VIN filter.
APPLICABLE WARRANTY
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
For 2023 Model Year RAV4 Hybrid vehicles equipped with a California Certified Emission
Control System that are registered and operated in California or any state that adopts California
emission warranty — California Emission Long-Term Defect Warranty is in effect for 7 years or
70,000 miles from the vehicle’s in-service date, whichever occurs first. (Please reference Policy
4.7, and/or the Owner’s Warranty & Maintenance Guide for additional information)
For Mexico Market
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
EG2407
R & R Fuel Tank Assy
2.0
77001-0R###*
87
13
*Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired
by searching for the parts in the Electronic Parts Catalog using the VIN filter.
APPLICABLE WARRANTY
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for
36 months or 60,000 kilometers, whichever occurs first, from the vehicle’s in-service date.
Warranty application is limited to occurrence of the specified condition described in
this bulletin.
Parts Information
PART NUMBER
PART NAME
QTY
77001-0R101
Tank Assy, Fuel
1
77169-#####*
Gasket, Fuel Suction Tube Set
1
77656-06030
Cushion, Fuel Tank, No. 6
5
72693-06030
Hook, Rear Seat Cushion Lock
2
*Use the correct part number by searching in the Electronic Parts Catalog using the VIN filter.
© 2024 Toyota Motor Sales, USA
T-SB-0042-24
May 1, 2024
Page 4 of 5
Fuel Gauge Does Not Read Full After Refueling
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
QUANTITY
Measurement Scale (Caliper or Ruler)
1
Repair Procedure
Figure 1.
1. Confirm the condition.
Does the fuel gauge read between 3/4 to 7/8
full after fully refueling as shown in Figure 1?
YES — Continue to step 2.
NO — This bulletin does NOT apply.
Continue diagnosis using the
applicable Repair Manual.
2. Remove the fuel tank.
Refer to TIS, applicable model and model year Repair Manual:
2023 RAV4 Hybrid:
Engine / Hybrid System – A25A-FXS (Fuel) –
Fuel Tank (w/ Canister Pump Module) – Removal
3. Inspect the fuel tank for deformation at the fuel suction unit flange. This may cause one side to
be lower than the other, as shown in Figure 3.
NOTE
The exact location and severity of the deformation may vary.
Figure 2. Fuel Suction Unit in Normal Condition
Figure 3. Deformed Fuel Suction Unit
1
c
1
© 2024 Toyota Motor Sales, USA
Example of Deformation in the Fuel Tank
T-SB-0042-24
May 1, 2024
Page 5 of 5
Fuel Gauge Does Not Read Full After Refueling
Repair Procedure (continued)
4. Using a caliper or ruler, measure the height of the fuel suction unit flange from the bottom of
the tank, as shown in Figure 4. Measure at multiple points around the flange to find the highest
and lowest readings.
Is the height of the entire flange 170 – 175 mm as shown in Figure 5?
YES — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
NO — Continue to step 5.
Figure 4.
Figure 5.
1
3
2
1
Fuel Suction Unit Flange
2
Bottom of the Fuel Tank
3
170 – 175 mm
5. Replace the fuel tank assembly.
Refer to TIS, applicable model and model year Repair Manual:
2023 RAV4 Hybrid:
Engine / Hybrid System – A25A-FXS (Fuel) –
Fuel Tank (w/ Canister Pump Module) – Installation
6. Confirm the condition no longer exists.
© 2024 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0042-24
Replacement Service Bulletin Number:
MFR Communication Date: 2024-05-01
MFR Internal Campaign ID/Software Version: T-SB-0042-24
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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