I can never pump more than 11.xx gallons of fuel into the car. I went as low as 7 miles to "Distance to Empty" (way past the fuel warning light) and still only able to pump 11.xx gallons. Toyota dealer did the Toyota directed changes for this issue (fuel tank replacement, some sensor replacement, etc.) but we are still having the problem. I showed it to the dealer with pictures, gas receipts, etc. as they requested but to avail. I then contacted Toyota and their response was that if the dealer is saying there is nothing they can do then nothing else to be done.

According to Toyota, the dealer had determined using their tools that there is 14.8 gallons of fuel in the tank. But they never tried what a normal user does which is to pump gas when the indication shows that the tank is almost empty. To me, what the dealer is seeing may be correct but if they don't test like a user then they don't see the actual problem. It could be that the tank has gas left over but the indication/gauges are wrong. The gauges are reporting that the tank is empty even when there might be additional gas in the tank. So, Toyota needs to either fix the gauges or the tank.

I am unable to get the fill my tank to full. The spec from Toyota says that the tank is capable of getting 14.5 gallons, however, the fuel pump only allows me to get around 12 gallons into the tank. The first time I didn't make anything of it cause it could have been a fuel pump issue. The next time I went to a different gas station and the same thing occurred.

The range on the car ends up being less because I can't get the entire amount of fuel into the tank. Its pretty annoying, and I hope Toyota can resolve the issue.

I've only owned this car for three months, but I noticed rather early on that my low-fuel light indicator would turn on when the dash computer reported I had about 30-40 miles to empty. OK, no problem. On Jan 23, the dash computer indicated I was 17 miles to empty, and the fuel gauge was not quite pointing at E, so I decided to stop for gas. So I filled it up (and topped it off) with 10.6 gallons.

This struck me as odd, because the car is supposed to have a 14.5-gallon tank. So, either my RAV4 is giving me a low-fuel warning when there's still 1/3 of a tank ( >4 gallons left), or my tank is much smaller than advertised. After the fill, the dash computer reports that I have ~400 miles to empty.

Coincidentally, my MPG indicator reports that I'm getting only ~32 mpg, which is about 20% lower than I expected given that I've been driving a Prius for 15 years and know how to drive a hybrid effectively.