I have the Grand Highlander hybrid max limited and am averaging around 23 mpg for daily driving. The gas tank max capacity is supposed to be 17 gallons but I am only able to put in a max of 12.5 gallons once the low fuel light comes on. Is there a large reserve tank and do I have an extra 4.5 gallons of range left when the low fuel warning light comes on? Please let me know how many gallons you are able to put into your tank once the low fuel light comes on (I still had 19 miles of range left once the low fuel light came on). Thanks!
Fuel Tank capacity issue
Grandmart
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Had a little road trip with our Limited Hybrid GH over the weekend and decided to push the empty light a bit, filled up after driving 36 miles past the DTE said "Refuel" and was still only able to get 14.42 gallons in with one squeeze after the first click.
What's the most distance anyone here has driven past "Refuel" and/or the most gas you were able to get in the tank (along with number of clicks of the pump handle if known)?
What's the most distance anyone here has driven past "Refuel" and/or the most gas you were able to get in the tank (along with number of clicks of the pump handle if known)?
Same issue on GH Hybrid Max Platinum. I have never been able to get more than 12 gallons in it. Last time, I was down to 70 miles and was not even able to get 10 gallons in. It is always showing around the 25mpg range. Currently, the gauge shows full with only a 277 mile range. When I check online, for some reason it shows the Fuel Level 232%. So things are not correct. Attached.
Attachments
So it looks like you have the same gauge issue as most in this thread. It would be nice if there was an OTA update fix or dealer software update. I'm sure Toyota is not concerned since this is a guaranteed way that no one will run out of fuel. It is really a very minor owner complaint since there are tens of thousands of others who are unable to get their Toyota Grand Highlander because of such high demand. Maybe that is why Toyota said to the one GH owner complaining to just have the dealer buy your GH back. There are plenty out there waiting. They are an awesome vehicle! I'm still unsure why they advertise it so much as a family vehicle. We are just the 2 of us and just like the room and rare option to haul kids and grandkids.
I decided to do an assessment on my fuel tank capacity. I ran the vehicle to empty. Yes completely empty. I carried a container with me so I had around two gallons in the container for when I finally ran out
The low fuel warning light came on. At this point the manual indicates I have 2.5 gallons or less remaining in the tank.
The DTE = zero came on after that of course.
From Low Fuel Warning to empty I drove 83 miles. My car gets around 25 mpg at this type of driving so that indicates around 3.3 gallons was left at that point - more than the manual expects.
From DTE=0 to empty I drove 67 miles so that indicates about 2.7 gallons was remaining at that point
At shutdown I added 2 gallons. The DTE came up to 3 miles which is not consistent with the numbers on the way down but not a huge difference (less than a gallon)
I drove a very short distance - maybe a mile - to a gas station and filled up. I clicked offs several times and could finally see a little fuel in the filler neck so I stopped. I pumped 16.1 gallons.
So allowing for a little consumption on the way to the gas station, the tank held 18 gallons (2 from the container and 16 from the gas station). This in fact is more than the manual says (17.2 gallons) but of course some will be concerned I flooded the vapor system.
My conclusion: There is not a capacity issue with the gas tank. Maybe some issues with the filler neck (clicking off easily). Certainly a conservative warning light since there are still at least two useable gallons in the tank after warnings.
On side information, some of course will say don't run to empty since there is a risk of sediment and filters plugging etc. With a new car I didnt figure that was a problem. I was able to drive the car a few hundred yards on battery power (to get to a safe refill parking) even after the gasoline engine shut down. The "engine has shut down, refuel immediately" alarm did not clear immediately. After I put in a couple of gallons and restarted the vehicle the alarm came on again. It referenced "see owner's manual" but a quick check of the owner's manual didn't tell me anything. I turned off the vehicle and started it again and all the alarms cleared.
Again pardon the pun, but ymmv
The low fuel warning light came on. At this point the manual indicates I have 2.5 gallons or less remaining in the tank.
The DTE = zero came on after that of course.
From Low Fuel Warning to empty I drove 83 miles. My car gets around 25 mpg at this type of driving so that indicates around 3.3 gallons was left at that point - more than the manual expects.
From DTE=0 to empty I drove 67 miles so that indicates about 2.7 gallons was remaining at that point
At shutdown I added 2 gallons. The DTE came up to 3 miles which is not consistent with the numbers on the way down but not a huge difference (less than a gallon)
I drove a very short distance - maybe a mile - to a gas station and filled up. I clicked offs several times and could finally see a little fuel in the filler neck so I stopped. I pumped 16.1 gallons.
So allowing for a little consumption on the way to the gas station, the tank held 18 gallons (2 from the container and 16 from the gas station). This in fact is more than the manual says (17.2 gallons) but of course some will be concerned I flooded the vapor system.
My conclusion: There is not a capacity issue with the gas tank. Maybe some issues with the filler neck (clicking off easily). Certainly a conservative warning light since there are still at least two useable gallons in the tank after warnings.
On side information, some of course will say don't run to empty since there is a risk of sediment and filters plugging etc. With a new car I didnt figure that was a problem. I was able to drive the car a few hundred yards on battery power (to get to a safe refill parking) even after the gasoline engine shut down. The "engine has shut down, refuel immediately" alarm did not clear immediately. After I put in a couple of gallons and restarted the vehicle the alarm came on again. It referenced "see owner's manual" but a quick check of the owner's manual didn't tell me anything. I turned off the vehicle and started it again and all the alarms cleared.
Again pardon the pun, but ymmv
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Have you noticed any differences in how the fuel gauge responds now that you've filled it up?
Wow, thanks so much for the update. I think you're the first owner that's run the vehicle to fully empty that had detailed numbers to provide.
Do you have the regular hybrid or hybrid max? I suspect likely the hybrid max with 25 mpg. I've average 34 mpg (6.9 l/100km) over the year and ~ 20,000 miles (32,000 km), I've had my GHH. I once drove about 51 miles (82 km) past DTE = 0 with 'Refuel' indicator on but chickened out driving further.
Also good to know after you ran out, you were able to get the vehicle moving again with only 2 gal and not needing an obd2 dongle to clear the error codes
Thanks for your effort in researching this!
Minor nitpick, it would have been interesting to note the gallons filled after one or two clicks as most people would fill their tanks. Regardless, it's still useful information!
My test on fuel tank capacity was a couple of months ago. Nothing has improved since then. When I took the car into the dealership it was kindof "too bad, so sad but we are not going to do antything and anyway you should not click off the pump more then once bceause you may flood the charcoal canister and get a CEL"
We similarly have been frustrated only put 11-12 gal in with the low fuel warning on in our GHH limited. I did get my dealer to start a TAS case and try and remedy the situation. They apparently only actually did the second time I brought it in... They then told me they recalibrated the sending unit and thought it had 6.2 gal when I left. They asked me to fill it up right away and send them a video of it. They expected it to take 11 gal, it tool 9.7. I was suprised the next fillup around 15 dte took 13.5 gal when the pump shut off. Some movement in the right direction.
I took it back a third time and Toyota directed them to replace the sending unit. Howerer they reported the new and original units both tested and reported the same. So, the note says they left the original installed. When I picked it up they thought the tank was too small. The tech thought it had 1/3 tank (~5.5 gal) and they filled 8.3 gal testing themselves. A couple days later they emailed me that the sending unit doesn't read the first 2.5 gal reserve. So, they now think it adds up.
Unfortunately their math is wrong. If the sending unit only measures 2.5gal to 17.2gal then 1/3 tank is 14.7/3 = 4.9 gal (not 5.5) + 2.5gal reserve. Leaving their total only 15.7 (4.9 + 2.5 + 8.3). It seems like their logic is flawed that they don't actually know the amount of fuel in the tank. They are basing it off of the sending unit, which is in question.
So, I decided to try and test the capacity myself by siphoning it out. It turns out you can siphon the gas out of the tank with a 1/4" pex line. So, I drained the tank when it was down to 1/3 again. (FYI I don't recommend the 1/4" is very slow. It took nearly 3h). I pulled 7.25 gal, but I don't think it drained fully, as it still started and ran fine for a few minutes after (I tried parking on an incline to get more out). Interestingly it continued to state 1/3 tank while moved it around empty. Not wanting to run completely dry, I put 2.5 gal back in, drove to the nearest station (2.1 miles away). It listed a DTE of 15 miles when it started and 13 at the pump. The low fuel light was on the whole way and it accepted 14.01 gallons when the pump shut off.
So, I confirmed the tank holds at least 16.5 gal. I think it likely had the remaining 0.7 below where my siphon could reach, or in a depressed/compartment near the pump pickup. Especially with the earlier report of 18 gal when running completely dry, and the DTE of 15 after adding 2.5 gal. If there is a 2.5 gal reserve the sending unit doesn't know about, it makes sense that it registered that it still had ~0.5gal above that reserve.
There is the chance that my tank is slightly smaller and others larger. Doing some reading it on various sources, I found its common for vehicles to be +/- 3% of stated capacity due to manufacturing tolerances. That could swing 17.2 +/- 0.516 gal. So, it's possible my capacity is slightly diminished, but not the 1.5 gal based on their math (17.2 - 15.7). Planning to follow-up with the dealer after our next tank/fillup.
I took it back a third time and Toyota directed them to replace the sending unit. Howerer they reported the new and original units both tested and reported the same. So, the note says they left the original installed. When I picked it up they thought the tank was too small. The tech thought it had 1/3 tank (~5.5 gal) and they filled 8.3 gal testing themselves. A couple days later they emailed me that the sending unit doesn't read the first 2.5 gal reserve. So, they now think it adds up.
Unfortunately their math is wrong. If the sending unit only measures 2.5gal to 17.2gal then 1/3 tank is 14.7/3 = 4.9 gal (not 5.5) + 2.5gal reserve. Leaving their total only 15.7 (4.9 + 2.5 + 8.3). It seems like their logic is flawed that they don't actually know the amount of fuel in the tank. They are basing it off of the sending unit, which is in question.
So, I decided to try and test the capacity myself by siphoning it out. It turns out you can siphon the gas out of the tank with a 1/4" pex line. So, I drained the tank when it was down to 1/3 again. (FYI I don't recommend the 1/4" is very slow. It took nearly 3h). I pulled 7.25 gal, but I don't think it drained fully, as it still started and ran fine for a few minutes after (I tried parking on an incline to get more out). Interestingly it continued to state 1/3 tank while moved it around empty. Not wanting to run completely dry, I put 2.5 gal back in, drove to the nearest station (2.1 miles away). It listed a DTE of 15 miles when it started and 13 at the pump. The low fuel light was on the whole way and it accepted 14.01 gallons when the pump shut off.
So, I confirmed the tank holds at least 16.5 gal. I think it likely had the remaining 0.7 below where my siphon could reach, or in a depressed/compartment near the pump pickup. Especially with the earlier report of 18 gal when running completely dry, and the DTE of 15 after adding 2.5 gal. If there is a 2.5 gal reserve the sending unit doesn't know about, it makes sense that it registered that it still had ~0.5gal above that reserve.
There is the chance that my tank is slightly smaller and others larger. Doing some reading it on various sources, I found its common for vehicles to be +/- 3% of stated capacity due to manufacturing tolerances. That could swing 17.2 +/- 0.516 gal. So, it's possible my capacity is slightly diminished, but not the 1.5 gal based on their math (17.2 - 15.7). Planning to follow-up with the dealer after our next tank/fillup.
Wow, so we have one owner that drove 67 miles (to engine shutoff) and another 51 miles (and chickened out. I chickened out at 1 miles past DTE=0...) past DTE = 0. Thank you both for taking one for the team and sharing the info. I think that's what most of us have suspected that there should be a couple of gallons left at DTE = 0. This will give me some peace of mind when I'm driving in the middle of nowhere and can't find a gas station that the car still got a stash of reserve gas to give me maybe another 70 miles on my GHHL even when it's showing 0. But still kind of scary, in case the issue got fixed over the air and I didn't know, and I actually have an empty tank... Toyota, please just fix it and give us a huge popup on the infotainment screen to let us know...
My conclusion was that the tank is probably the right size. The issue is there is too much unusable at the bottom and there is too little fillable at the top.
While some early complainers got some attention that didnt fix anything, anything recent just gets rejected as an issue by the dealership and by Toyota.
YMMV
While some early complainers got some attention that didnt fix anything, anything recent just gets rejected as an issue by the dealership and by Toyota.
YMMV
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285 Posts
Welcome to the forum @Hawk37. Thanks for sharing this. It's interesting to see it different depending on the manufacturing. Are you liking the Grand Highlander overall aside form this?
There seems to be evidence here that it's not an issue with some capacity being "unusable", more that the gauge reads 0 DTE with 2-3 gallons left in reserve. I was able drive 36 miles past 0 DTE, 459 total miles on the tank, and was only able to add 14.4 gallons to the second pump click.
Technically correct in that if you are prepared to run out every time: I can run at least 3 gallons below DTE=0. But if this 3 gallons is left alone (because of screaming kids saying we are all gonna die on the freeway) and you dont fill past one pump click (because my service manager says he will charge big $$$ to clear the CEL) you are probably limited to a usable volume of 13 gallons.
I used ~1 gallon of it so I wouldn't say its "unusable" 🤷🏼‍♂️
Unusable would mean to me that it's below the inlet point in the tank and can't be drawn out by the fuel line.
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