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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Kind of sad to know that one has to file a formal complaint to get things done or get some traction. Did the head of service tell what was the outcome with the Highlander issue? Were they able to fix it? @GHPlatMax
I dropped by GH Hybrid today at the dealer to get the fuel tank replaced. I've been told by the dealership that this won't resolve the problem, they've to send the tank to Toyota engineers (wherever that may be), but I'm not expecting any positive resolution to this in the near future based on everybody else's experience.
I have had the fuel tank replaced and now I’m waiting on another part to replace the “neck”? I believe that’s what they called it, who knows but I’m just glad they’re trying to fix the issue at this point! Since getting the tank replaced I’m only getting 230 miles to the tank and around 20MPG. It’s trash, my husbands Tacoma is getting better gas mileage at this point.
That is indeed pathetic! Vehicles with smaller thanks get range than 230 miles. I got the tank replaced today and will have to see what difference it has made, as hasn't driven much yet. When I asked about the next step from here, the dealer said it's a wait and watch game as the engineers will study the original tank.
Same, would like to know if the issue is with the tank vs the gauges. Have 5k miles on mine, solidly averaging 22-23 city driving. Max fill up with "4 miles to empty" was 14 gallons, and that was after the nozzle shut off multiple times because of a "full" tank. Still told me 325 miles til empty - no where near the advertised - and with the mileage I'm getting, I haven't gotten over 300.
You are correct, it'd not change anything. The dealer told me replacing the tank is not going to fix the issue, they wanted to get the tank sent to Toyota engineers to study and troubleshoot it. My question was that if it's the same tank, why even swap, cannot they study that without removing the original one? There was no answer to that question...in any case I couldn't say no to removing the tank as they're trying to fix the issue and I don't want to be in a situation where they could say we offered you help but you did not accept.....
changing the fuel pump did not help what so ever. Also I run mine anywhere from 50-60 miles below Refuel but that’s the farthest I’ve pushed it. I would push it even farther but my husband won’t let me drive around with a gas jug in the back in case I ran out. He says it’ll make the inside of the car smell like gas 🙄 and I don’t want to be stuck on the side of the road.
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This sounds like the very same pitch I got from my dealer. “Let the car break in.” lol Then what? I’ll be able to fill up the advertised amount of fuel?
And hybrids are identical in city and hwy mileage. not opposites. They do better on both compared to gas.
I have 10k mileage on my grand Highlander limited with the max engine. I get around 24mpgs but my range is terrible. ~300 miles a tank and then only being able to fill ~11 gallons. Quit trying to discredit so many peoples similar issue. You sound like a dealer that doesn’t want to deal with a manufacturer flaw.
Just as a point of reference for everyone, yesterday I filled up when my gas gauge read 1/8 of a tank remaining and 42 miles left on DTE. I put 13.6 gallons into it. 7/8 of a 17.2 gallon tank is 15.05 gallons so my fudge factor (reserve) seems to be just under 1.5 gallons. That seems reasonable.
If I'm correct and your GH is gas only, your experience is how the vehicle 'should' be.... however, the gas only versions of the GH aren't affected by the fuel tank capacity issue... only the hybrids and hybrid max. I doubt, you'd find anyone on the forum with hybrid/hybrid max that's been able to fill up much more than 13 gal from when the low fuel light comes on.
In the case of my GH hybrid limited,I again called Toyota Canada (also called back in November) to see if there's been any updated information, and not surprisingly the rep again said its the first time they've heard of the fuel tank capacity issue on GH hybrids so that was a waste of time.
The only hope is folks in the US continuing to report the problem to US dealerships and Toyota US for there to be any hope of a resolution.
I'm still getting great gas mileage on my GH hybrid limited but also visiting the gas station way more often than I should.
You are correct. I have the 2.4L I-4 gas only version. Definitely less visits to the gas station than my Tacoma that I traded in 
Update to the updates.
The Toyota dealership told me that when they removed my gas tank and fuel pump, they sent that one to Toyota engineering to be “looked at”. I do not know if this is true. But it is still an “open issue” so the dealership said they would contact me with an update when they have an from Toyota.
I took it upon myself to start driving past the Refuel indication and start tracking.
I’m using Trip A and doing the reverse mileage. I’m driving no more than 350miles (except one time).
Here’s hoping they come up with a resolution for this.
Greetings! I wanted to add that we are also experiencing this....I think I must have come across this thread before we purchased our GH Hybrid Max Platinum, so the first time I filled up and the pump clicked off at 12 gallons I realized this was unusual but something other owners have realized. On my first refill we did actually have 26 mpg, this tank is slightly lower, I think 23-24ish, but I think I've only driven about half the tank so far...I love statistics, so I'm going to start watching closely & tracking my trips, refills, etc.
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So I had same issue with my 2024 grand highlander, and took it and the Toyota notice about issue to Toyota service dept. They said they had just been briefed by Toyota issue this week, and no fix available yet. They kinda told me toyota would be coming out with a fix....Dan
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I don’t know if this is a issue but, here is the observation with my GH Hybrid Limited from my recent trip, I refuelled at 35 miles to empty and the gas shut off after taking in approx 12 gallons, however with manual push I was able to pump in another 2.5g so in one refuel I was able to pump in 14.5g
GHHL on our eclipse road trip - 3 miles remaining, then 13.8 gal to refuel (includes one top-off pull just to be sure, otherwise I don't do this). Capacity is 17.2 gal? So ~3-3.5 gal reserve? But is it usable, or was I on the verge of stalling by the roadside?
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