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
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Grandmart
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How has your communication with the dealer been throughout this process? Do you feel like they’re taking your concerns seriously?
Yes, its been otherwise great!
It's been poor. It was only on the second time when I showed them the tech note to open a case that they actually did it. They claimed they didnt have any notes of doing it the forst time and had to restart. Another owner posted that their dealer fixed the issue on Reddit. They can now fill 14.4 gal. So, I brought them that on my return visit. They said they couldn't act on that and had to follow the process with Toyota because it is the first model year. After they got to the sending unit they told me they'd be in touch with toyota again on Monday (finished on Saturday). A few days later they forwarded me the service record saying they think it's working correctly now with wrong math I described. Now they're texting me for a survey like they think it's resolved.
I would say the recalibration helped. Seems like it got us another gallon before the low fuel warnings start now. They
mentioned it was common, and they didn't have to take anything apart to do it. You just have to get the dealer to care. They should follow their own instructions and start a TAS case like their tech tip recommends.
For awareness, here is the tech tip the dealer should follow. Also a fellow owner on reddit posted their dealer replaced the sending unit and they were able to fill 14.4 gal on their next fillup. Reddit post
My dealer also attempted to replace the sending unit, but from their confusing notes its sounds like they concluded the new one read the same as the original and reinstalled the original. I don't think they tested it thoroughly or at empty like the notes from the fix. The tank was around 1/3 when they had it. They had to remove both rows of rear seats to access it. They ripped the headliner, which I'm hoping they'll deal with when they have to pull it for the recall.
In response to your edited post, it would seem Toyota could recalibrate the gauge sensor to add 30-60 miles to the end of DTE. Until then, I know I won’t feel my normal urgency to find a gas station when I see <50 DTE.
That said, after filling, DTE typically reads ~530 miles which is inline with a 16-17 gallon tank, but goes down somewhat faster than the miles traveled.
Mine has been in for investigation, and the service dept wont/cant do anything re calibration. I have just completed a long (2000 mile) trip and like you, I am no longer in a hurry to fill up until I hit DTE=0. BUt the issue after that is that, unless you make copious notes, it is easy to forget at which Odometer reading DTE was zero and therfore how much longer I can drive before refill. The sphincter gets a lot tighter after just a few minutes of ""Zero miles left ... FILL UP NOW"" And of course on a long trip I dont want to pull off any earlier than I have to.
So yes I modified my note while you were immediately responding, but I stll hold on to the concept that the full tank capacity is unusable.
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All this said, I have tried to contact Toyota directly but only got a response thanking me for my interest. No answers to my questions about the fuel issue. I get a shoulder shrug from the dealer and then an explanation from a service advisor that it has 4 gallons of reserve fuel. I asked him why the gauge doesn’t show that and he did not have a good answer. Does anyone know how to contact Toyota other than the website??
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There's an 800 number you can try if you haven't already
800-331-4331
Contact Us | Contact Toyota
Contact us. Whether you're a Toyota owner or just have a question about our products, select the most convenient way to reach us, and we'll do our best to help you.
Hi all! I posted this on another thread, but thought I would share my similar experience. We bought a '24 Grand Highlander XLE Hybrid back in December of 2023. Our previous vehicle was a '23 Highlander Hybrid. We opted to trade in for the grand highlander for the added space.
Like most of you, we noticed within a couple months that we were only being able to pump 11 to 12.5 gallons in the tank at each fill up when the DTE was registering 30 miles or less. Knowing that the GH has a 17.2 gallon tank with a 2.6 gallon published reserve, we theoretically should be able to fill 14.6 gallons in the tank at 0 DTE. So that was leaving us a couple gallons shy of that mark. I created a spreadsheet to track data at each fill up and have been adding to it for almost a year now. The data supports the issue that the vehicle is telling us to refuel well before it should.
This seems like a mild annoyance that you just deal with, but it frustrated us because the 2023 regular highlander hybrid didn't have this issue. We were regularly able to pump around 14 gallons at each fill up, and the fuel tank capacity was similar (slightly less) at 17.1 gallons. Knowing the GH and regular hybrid share a similar platform, why was this now an issue on the GH? People buy hybrids for the fuel economy (which we are getting), and also for the range it affords. The range is unnecessarily being cut short by and inaccurate low fuel warning.
We took the vehicle in to two different dealerships to look at the issue. Both came back saying the fuel system was working as designed. The last dealership recommended that I call the Toyota Engagement Center to report the issue, which I recently did. They took my information and created a case. I shared my data with them, but that's as far as they are taking it at this point until enough people report the issue to facilitate the issuance of a technical service bulletin. I referenced the tech tip about this issue mentioned earlier in this thread, but the reply I got was that the tech tip had expired. My response was that just because a document expires, it doesn't mean the issue magically no longer exists! I kind of expected more from Toyota, but I guess I was being naive. Hopefully the issue will be elevated as more people complain, but I'm not going to hold my breath at this point.
Like most of you, we noticed within a couple months that we were only being able to pump 11 to 12.5 gallons in the tank at each fill up when the DTE was registering 30 miles or less. Knowing that the GH has a 17.2 gallon tank with a 2.6 gallon published reserve, we theoretically should be able to fill 14.6 gallons in the tank at 0 DTE. So that was leaving us a couple gallons shy of that mark. I created a spreadsheet to track data at each fill up and have been adding to it for almost a year now. The data supports the issue that the vehicle is telling us to refuel well before it should.
This seems like a mild annoyance that you just deal with, but it frustrated us because the 2023 regular highlander hybrid didn't have this issue. We were regularly able to pump around 14 gallons at each fill up, and the fuel tank capacity was similar (slightly less) at 17.1 gallons. Knowing the GH and regular hybrid share a similar platform, why was this now an issue on the GH? People buy hybrids for the fuel economy (which we are getting), and also for the range it affords. The range is unnecessarily being cut short by and inaccurate low fuel warning.
We took the vehicle in to two different dealerships to look at the issue. Both came back saying the fuel system was working as designed. The last dealership recommended that I call the Toyota Engagement Center to report the issue, which I recently did. They took my information and created a case. I shared my data with them, but that's as far as they are taking it at this point until enough people report the issue to facilitate the issuance of a technical service bulletin. I referenced the tech tip about this issue mentioned earlier in this thread, but the reply I got was that the tech tip had expired. My response was that just because a document expires, it doesn't mean the issue magically no longer exists! I kind of expected more from Toyota, but I guess I was being naive. Hopefully the issue will be elevated as more people complain, but I'm not going to hold my breath at this point.
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Folks,
I've had my 2024 Grand Highlander into multiple Toyota service at dealerships five times to address the fuel tank issue. Again, I have never been able to fill my tank with more than 12.7 gallons. Service technicians have no idea what the problem is, but keep giving me trained responses regarding the issue. One: If there was a real issue Toyota would issue a recall. Two: It's a reserve issue (seriously 1/3 of the tank). The gauge has been adjusted, it should be better. It's lies. Toyota know there is a problem. The fix will be difficult as it was with the RAV4, my wife and daughter-in law both had fuel systems replaced. I would like to have the defect repaired, but I cannot find a local repair shop that is willing to address the Toyota error. I'm not sure if I should get an attorney or just wait on a recall. So frustrating, My wife & I have had Toyotas for over 40 years. Such a great brand, now we see it as equivalent to Dollar Store, Edsel, Walmart electronics, and now Toyota gas tanks. So disappointing and embarrassing for Toyota.
Phil Newton
I've had my 2024 Grand Highlander into multiple Toyota service at dealerships five times to address the fuel tank issue. Again, I have never been able to fill my tank with more than 12.7 gallons. Service technicians have no idea what the problem is, but keep giving me trained responses regarding the issue. One: If there was a real issue Toyota would issue a recall. Two: It's a reserve issue (seriously 1/3 of the tank). The gauge has been adjusted, it should be better. It's lies. Toyota know there is a problem. The fix will be difficult as it was with the RAV4, my wife and daughter-in law both had fuel systems replaced. I would like to have the defect repaired, but I cannot find a local repair shop that is willing to address the Toyota error. I'm not sure if I should get an attorney or just wait on a recall. So frustrating, My wife & I have had Toyotas for over 40 years. Such a great brand, now we see it as equivalent to Dollar Store, Edsel, Walmart electronics, and now Toyota gas tanks. So disappointing and embarrassing for Toyota.
Phil Newton
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Even when adding the extra the total amount never exceeds 13 gallons and the tank is supposed to hold 17.1 gallons. This is when the fuel gauge shows only 40 miles left
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My dealer never has acknowledged this. They tried to explain it as temperature related
I think on a different thread it was posted the sending unit in fuel tank has a resistor (or something) that's not correct for this size tank, changing the sending unit may had corrected the issue but new units off the shelf were also found to have the wrong resistor with the same part number.
I know I've filled the tank & when I'm at DTE=0 or "Fill tank" message appears I still have 4+ gallons. In GHHL I can go another 100 miles (reset tripometer B at this point) before getting in to "Reserve" range.
I know I've filled the tank & when I'm at DTE=0 or "Fill tank" message appears I still have 4+ gallons. In GHHL I can go another 100 miles (reset tripometer B at this point) before getting in to "Reserve" range.
Just got the new 2025 GH Hybrid Limited. Have had it for a week and a half and same issue as all of you. Have filled up 3 times with this morning giving me the most at 11.4 gallons with 44 miles to empty showing. So clearly they did not fix anything with the 2025 from the 2024 model. How is Toyota not fixing this? For those of you who have been through it...suggestions? Do I take it to the dealer and complain (I bought it in MI but live in WI so would have to find a dealer here)? Do I contact Toyota to complain?
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This is my 3rd post about gas tank capacity. After another 500 mile trip, I am convinced that my gas tank is not a 17.1 gallon tank. It is more like a 13 gallon tank. Has anyone had their tank tested and then replaced by the dealer under its warranty?
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