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I called my local dealer in Alberta, Canada where I bought my GH hybrid from and not surprisingly, the person in service said they haven't heard anything from other customers about issues with fuel tank capacity and haven't heard from Toyota Canada.

Granted sales of the GH are much lower in Canada than the US because of fewer allocations, and they only hit dealer lots at the beginning of September.

I called Toyota Canada to make an official complaint/documentation. I also booked a service appt with my dealer so we'll see what they say when they see fill ups have much lower than expected volume.
 
That's BS. It's a well documented issue with the 4th gen Highlander Hybrid. There's even a TSB addressing this.
To clarify, the Toyota Canada rep was familiar with the fuel capacity issues in other Toyota vehicles, but said it was the first time they've heard of it with the GH hybrid.

Hopefully, more owners report it to Toyota Canada so they realize it's a problem they can't ignore.
 
Driving my GH last weekend and was down to 30 miles left on the tank according to screen. When I stopped to fill up I was only able to get 13.5 gallons and that's with squeezing as much as I could get it. What's up??
Getting 25 MPG on first 3,000 miles according to guage on screen.
 
Driving my GH last weekend and was down to 30 miles left on the tank according to screen. When I stopped to fill up I was only able to get 13.5 gallons and that's with squeezing as much as I could get it. What's up??
Getting 25 MPG on first 3,000 miles according to guage on screen.
Congrats on getting your Grand Highlander @jgeary1206 and welcome! How much fuel did you have left to fill after it stopped filling up? Has it happened before or since?
 
Driving my GH last weekend and was down to 30 miles left on the tank according to screen. When I stopped to fill up I was only able to get 13.5 gallons and that's with squeezing as much as I could get it. What's up??
Getting 25 MPG on first 3,000 miles according to guage on screen.
Can't tell you what's up, but you should be very careful topping off over and over to squeeze as much fuel in there as possible... first, because it might not actually be necessary (because it might be a fuel level sensor issue or an understated reserve capacity by Toyota, rather than not actually being filled to max. capacity)... but, mainly, because doing so might really damage your car, flooding the charcoal canisters, clogging up the catalytic converter, killing the emissions system, etc. Car Care Nut has some good videos on this topic on YouTube.
 
I am having the exact same fuel capacity issue with my Grand Highlander Hybrid !
What are you experiencing? Not being able to put in as much gas as you expect to be able to at the pump? What does your range to empty say immediately after you've filled up? Does your fuel gauge reach the F, or stop short of F? Thanks.
 
The other day it said I had 18 miles of range remaining. The gas pump clicked at 11 gallons and I the coaxed another 2 gallons in to the tank. I called the dealer service and they referred me to my sales person. The salesperson said that the Toyota has a 4 gallon reserve which I called BS on ! The service dept will not call me back after two requests. I have had the vehicle for 4 weeks and have approx 2000 miles on it. Every fill at the gas station has the same results!
 
My range immediately
What are you experiencing? Not being able to put in as much gas as you expect to be able to at the pump? What does your range to empty say immediately after you've filled up? Does your fuel gauge reach the F, or stop short of F? Thanks.
after filling is randon and nowwher near capacity. Though after a minute it will show full and a rang of 357 miles which also does not make sense since MPG shows 24, this should give me a range of approx 400 miles per tank
 
The guage on the dashboard showed that I had 30 miles before empty. The fuel guage was almost at empty. I'm guessing I had 1-2 gallons of fuel in the tank. Thant amount plus the 15.5 gallons that I stuffed into the tank brings it to 15.5 gallons. It happens all the time and don't understand why. It's the first time I let it run down that far.
 
The guage on the dashboard showed that I had 30 miles before empty. The fuel guage was almost at empty. I'm guessing I had 1-2 gallons of fuel in the tank. Thant amount plus the 15.5 gallons that I stuffed into the tank brings it to 15.5 gallons. It happens all the time and don't understand why. It's the first time I let it run down that far.
All I can say at this time is what I speculated in reply to your post above… may actually be an issue, may just be an inaccurate reading, or could be due to an understated reserve capacity.
 
And potentially up to 4+ gallons in reserve… either by design, or due to inaccurate fuel level readings from miscalibrated fuel level sensors.
It's by design and reserve is about 2.6 gallons which is reasonable imo. This is to account for unreasonable segment of the population who will take it close to empty, run out of fuel and then sue the vehicle manufacturer for being left stranded.

What do you suggest?
 
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