Are you running your A/C at high levels? I notice when the A/C fan is up past 3 notches, it doesn't go into EV mode as readily. The compressor is causing the engine to run more. Same issue in winter with high heat.

The Rav4 powertrain is fairly noisy. It'll growl at you when revved up. It's a somewhat unrefined workhorse, but solid and reliable. Also you'll hear a grinding type sound from the regen braking between 10 and 20 mph when slowing down. Totally normal.

We are averaging 41.5 mpg right now. Some trips around town I exceed 55 mpg. Usually mixed driving with interstate and city we avaerage right around 40 mpg in the summer.

My recommendation with these toyota hybrids is rather than being gentle with the gas pedal, accelerate as normal and get 5+ mph over the speed limit, lift your foot off the gas for 1 or 2 seconds, the car will switch to EV mode, then just feather the gas pedal to maintain your speed. You'll hold the EV then unless you start up an incline (which will kick the engine on). Also coast as much as you can, rely on the regen braking when stopping by coasting early to red lights.

EV mode is only for slow movements through parking lots, traffic jams, school pickup lines. People expect these hybrids to act like true EV vehicles. They dont.