2019 Toyota RAV4

I am submitting this complaint regarding a recurring issue in the coolant bypass valve of my 2019 Toyota RAV4 XLE Premium. Although there was no check engine light, the vehicle displayed a persistent warning: “Engine Maintenance Required – Visit Dealership.” This message repeatedly appears on the instrument cluster and blocks critical driving information, including the speedometer, fuel economy, and other key displays. Even when the driver manually cancels the message, it returns within minutes. This creates a constant distraction and obstructs visibility, which poses a safety risk during driving. I took the vehicle to the dealership, where they diagnosed the issue as an internal short circuit in the coolant bypass valve and retrieved diagnostic trouble code P268115. This code relates to a malfunction in the valve’s electrical control system, which affects the engine’s ability to regulate temperature effectively. Toyota currently offers a Customer Support Program (CSP) for the coolant bypass valve, but only if the valve is leaking coolant. However, my vehicle's failure was due to an electrical defect, and Toyota does not cover this under the same program. This creates an unfair burden on owners and fails to address the full scope of the issue, even though the results—loss of proper cooling function—are the same. Many RAV4 owners have reported similar problems online, but no recall or technical service bulletin has been issued for this kind of failure. I believe this defect raises genuine safety concerns, including: Driver distraction due to persistent warning messages Obstruction of critical dashboard information Potential for engine overheating or reduced performance I respectfully request that NHTSA investigate this issue as a potential safety-related defect and determine whether Toyota should be required to expand support or issue a recall for this component, regardless of whether the failure is due to coolant leakage or internal electrical malfunction.

The vehicle began displaying intermittent warning messages and slipping into "Mud & Sand" mode without cause. Later, multiple dash lights illuminated, including 4WD malfunction, check engine, and coolant system warnings. The vehicle became undrivable due to overheating. Dealership diagnostics indicated a failure in the coolant bypass valve actuator the electronic water pump was receiving a signal but not responding, resulting in loss of coolant circulation and overheating. There may also be a shorted control panel causing related system failures. This problem has been confirmed by a Toyota dealer, and the vehicle remains at the service center pending resolution. The issue appears related to a known Customer Support Program (CSP 24TE04), which covers the coolant bypass valve actuator. There was no prior accident or abuse of the vehicle, and the vehicle only has 52,000 miles. Safety was compromised due to unexpected power loss and overheating while in motion. The issue has not yet been resolved. The vehicle has also experienced prior water intrusion through the roof rails, which may have contributed to electrical damage.

Started normally, but had a message on the screen saying “Check Fuel Cap.” I needed gas anyways, drove about 3 minutes to the gas station, turned engine off, put gas. Turned engine back on and within 3 seconds it shut off. The screen displayed “engine stopped- Power steering low.” I tried a handful of times to start, it did not. After 20 minutes and some rest, it started. With no more messages. Battery and alternator were tested, both were good.

An error code titled “Engine Maintenance Required. Visited your dealer” appeared on my dash screen. The error code was unable to be removed. I attempted have the car diagnosed by a private auto shop, however no faulty codes pop up. After research online, the problem was determined to be the engine coolant valve, which are faulty on many Rav4s. I eventually get a letter from Toyota for a Customer Support Program regarding the Engine Coolant Valve. When brought in for maintenance, Toyota pulled the error code “P268115” which is for an internal failure of the engine coolant valve. However, Toyota will not replace the part due to their Customer Support Program (24TE04) only covering the part for “small engine coolant leak[s]”. Essentially, Toyota will replace the part for being faulty if it had small leaks, but not if the part itself is faulty. When I asked the service member I was working with stated that this is a known problem and “[Toyota] should have just replaced the whole part, but they only do it for small leaks.” Currently, litigation is proceeding regarding the engine coolant valve, alleging Toyota knowingly put faulty parts in their Rav4s. I urge you to investigate this claim.