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Fuel Tank capacity issue

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105K views 309 replies 70 participants last post by  MuSchu  
Same issue grand Highlander hybrid max, already at 31,000 miles. 2024 model. I do drive a lot. I use it as a work vehicle. After a full tank, the car keeps showing random mileage between 295 to 336.( after checking how much miles I could really do. It’s at 250 miles and I need to fill up because the tank is empty) buying gas. The car only does about 10 gallons of fuel. Then a fuel pump shuts off. My nearest Toyota stated that the fuel tank capacity is there 17 gallon tank and they keep saying Toyota needs to do a recall and nothing that my closest Toyota dealer could do.
 
If I run the tank all the way down to 8 miles the most I could put in is 11.25 gallons. Even though in the owners manual states the tank capacity is a little above 17 gallons probably like 17 1/4 but the car never even takes more than 12+
 
Sounds good, kind of disappointing with the hybrid battery only working when you’re driving 20 mph. Toyota should’ve stated something with that. The most problems I’m having with this car is with the fuel tank situation. I’m already at 33,000 miles and have the car for a little bit over a year. Use it as a work vehicle and constantly at the station about two times sometimes three times a week. On a full tank the most I can do is 280 miles when I am already very, very low on gas.
 
Sorry I wasn’t as focused on the mpg but the total estimated miles left in the tank—usually I can only go about 275-325 miles on a tank even though when I refill the (estimated) miles to empty is upwards of 360. And my number one gripe is the micro machine sized gas tank—I’m only able to get 10-12 gallons of gas per fill up! Eternally I curious why this vehicle has a 5-7 gallon reserve or why I can’t put more gas into the tank at every fill up! In the above tank I think it was my error that I never reset the trip odometer when I last filled up.
Max mileage I can do with only 8 miles left on the tank is 232. My local dealer stated it might be a software issue not the tank “ capacity is there “ as I am being told .
 
Interesting. I just left Toyota and they said the sending unit is too short and does not make a full dip after a bend in the tank. This is a known issue and there is no fix yet. However Toyota is aware but needs enough people to submit work orders for issue
Is there a way to find out how many people filed the same issue with Toyota ?
 
I have my Tsb Reflash Combination Meter scheduled for tomorrow morning at 9am , after 20 visits and 40K miles now ( 2024 hybrid max ) dealer stated they never tried that reflash after all these visits I had , hopefully tomorrow will be a positive outcome .
 
Quick update for everyone just received the car back with the new updated software. The vehicle had 162 miles left to empty. And only took 5.8 gallons of gasoline. Right now I’m showing only 360 miles total on the tank. Maybe you have to drain the gasoline all the way out and refill?? doesn’t seem like this update works
 
Just had it done today , 162 miles on the tank when my car was dropped, after software flash I was told to get gas and see what happens . Only5.8 gallon and 360 miles on total tank . Software didn’t do anything unless the tank needs to be drained down ????
 
Had the SW update done but haven't refueled yet. So TBD.

But I read elsewhere that w/ new SW, the tire pressure display now sticks after shutdown - would get overridden with a different display after a short period after shutdown. I noticed this worked after a few hours shutdown yesterday, can't wait to see if it remained overnight.
Good luck , update didn’t work for me at all after refuel same situation but I was told from one user on Reddit he said “ lets try a few more drains and re-fills for the AI to re-learn when the gastank is Empty and when gas tank is Full, and see if after several fills the AI allow you to fill up to 16gallons. “
 
With the second fill up, it’s showing me 29.9 miles to the gallon on the hybrid max. Which is kind of weird because it always stayed around the 24 miles per gallon so I guess that is working better but still not taking the amount of fuel it needs.