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I have seen a lot of talk about this subject and some folks just push it to the edge. You won't stall and have plenty more miles to go (just as a safety net). Have heard you don't want to stall it as it will require a tow to a dealer, filling up won't just start the vehicle, something needs to be reset if I recall. Coincidentally pushed my platinum a bit further than usual just this evening. Hit 0 which then showed "Refuel" and drove another 13 miles on the highway. Filled the tank up and the pump showed I poured 16.590 gal. of fuel meaning, I had another 1.21 gal. left in reserve (17.8 gal. tank). Did notice that it extended the fuel range so it now gives me an additional 10 miles when topped off.
 
Hi, All - I just filled my new GHHL for the first time. 342 miles on it, 53 left to go, and just over 12 gallons. Actual MPG = 28.5 (which matches the dashboard readout). I’m annoyed and hoping for a fix, and at the same time loving that I’m getting at least that mileage. I’m still super happy with the car.
 
Jumping in after one fill up since I'm interested in other's experience.

I do want to mention that squeezing every last drop into the tank is not recommended since it can damage the vehicle's ORVR system. I've changed to simply going to the second pump "click off". The extra fraction of a gallon I might get isn't going to improve anything.

 
I have seen a lot of talk about this subject and some folks just push it to the edge. You won't stall and have plenty more miles to go (just as a safety net). Have heard you don't want to stall it as it will require a tow to a dealer, filling up won't just start the vehicle, something needs to be reset if I recall. Coincidentally pushed my platinum a bit further than usual just this evening. Hit 0 which then showed "Refuel" and drove another 13 miles on the highway. Filled the tank up and the pump showed I poured 16.590 gal. of fuel meaning, I had another 1.21 gal. left in reserve (17.8 gal. tank). Did notice that it extended the fuel range so it now gives me an additional 10 miles when topped off.
Wanted to chime in that the fuel range on my GHHL has also increased. It used to be around 450 after filling up. Yesterday, it showed 500. Not sure if it got some kind of OTA update and it recalibrated or something else. But, I have been consistently only filling up 13-14 gallons when it showed almost 0 miles left. At 17.2 gallon capacity, that's more than 100 miles left in the tank... We'll see how much is needed to fill up after this tank gets used.
 
took ownership of GHHL in April, fill tank first time with about 30 miles DTE, took 12.09 gal, traveled 455 miles. fits in with everyone else's experience.
we're being told that there's a 17.2 gal tank with a 2.5 gal reserve at DTE.
if this correct, the tank isn't being filled completely. a design issue.
if the tank is full with adding 12 gal, the
"reserve" must be greater than 2.5 gal.
this may be a computer calibration issue with tank float or the wrong float for that tank.
either way it doesn't appear to be such a difficult problem that the great minds at toyota can't come up with a solution.
at least tell us if the tank is getting filled or not.
 
Just filled up the GHHL yesterday: 14.574 gallons after 502.9 miles traveled and gauge went just below 1 mile left. I still have about 90 miles left in the tank, but the gauge shows zero. After filling up, gauge indicate I can go 516 miles with the tank. Happy that I'm getting 34.5 MPG, just as advertised between 32-36 MPG for the Hybrid Limited AWD.
 
There's a guy that works at my local Toyota dealership in the service department who also had bought a GHHL and was experiencing the same problem (tank capacity). Two months ago when I spoke with him, he told me that Toyota's engineers are working on it and so there'll be a fix.

So I called him this morning to see if there's been any updates on the tank situation, which unfortunately is a no. However, I found out that he sold his GHHL back to the dealership citing the reason that he didn't need the vehicle anymore. I hope it's not because he knows there's no fix on this....that'd be a bummer.

I've had the GHHL for 5 months now with about 3.5k miles, and no changes to the amount of gas I can refill. I can only fill about ~12.5 gallons when the DTE reaches to 0. It seems my mileage has improved though and am getting around 34 per gallon versus 32 when I had gotten it a few months back.
 
There's a guy that works at my local Toyota dealership in the service department who also had bought a GHHL and was experiencing the same problem (tank capacity). Two months ago when I spoke with him, he told me that Toyota's engineers are working on it and so there'll be a fix.

So I called him this morning to see if there's been any updates on the tank situation, which unfortunately is a no. However, I found out that he sold his GHHL back to the dealership citing the reason that he didn't need the vehicle anymore. I hope it's not because he knows there's no fix on this....that'd be a bummer.

I've had the GHHL for 5 months now with about 3.5k miles, and no changes to the amount of gas I can refill. I can only fill about ~12.5 gallons when the DTE reaches to 0. It seems my mileage has improved though and am getting around 34 per gallon versus 32 when I had gotten it a few months back.
I can't imagine anyone so frustrated by this "issue" that they would trade in their GHHL. From the discussion here, it's not a matter of not being able to get 17 gallons in the tank, it's how much gas DTE thinks is in the tank which should be an easy software upgrade.

Personally, I've filled up 3 times so far and not been able to put in more than 12.6 gallons with 50 miles DTE. I definitely won't looking to fill up with 100 miles DTE for some time.

FWIW, when I fill up, I do one squeeze of the pump handle after it clicks off and stop. What's interesting is the last fill up, the trip ODO plus DTE was 396 + 50 = 446 miles. Shortly after getting back on the road, the trip ODO plus DTE has been ~480 miles. It would seem there's extra gallon in the tank vs. two fill ups ago which corresponds to the actual MPG I calculated being 5 MPG lower vs. the display MPG being 1 MPG higher.
 
I do want to mention that squeezing every last drop into the tank is not recommended since it can damage the vehicle's ORVR system. I've changed to simply going to the second pump "click off".
Thus far I've stopped at the first click off, but considering continuing for one more. Low risk if you stop there?
 
That's my perception, also thinking that some dynamics of the flow might cause an in adverting first click.
Yeah I've wondered if the first click could just be the fuel splashing itself off. Will give that 2nd click a try.

...Well going to that 2ns click only allowed for another 1/3 gal or so, not really worth bothering.
 
I'm also experiencing the same. I have a limited hybrid which I believe has 65L fuel tank capacity. Fuel economy has been great as with almost 2,000km, I'm averaging 6.3 L/100 km (~ 37 MPG) with mixed city / freeway driving. Range though is nowhere close to where it should be for the fuel economy and tank size.

My first fill up, I had 74 km left to empty but was only able to put in 40L before the gas pump auto shut off. My trip distance was about 690km.

My second fill up, I had 62 km left to empty and was only able to put in 43L before pump auto shut off. Both fill ups were at Costco pumps for what it's worth and the low fuel light didn't come on for either. My trip distance was about 680 km.

There's been some posts on another forum that some have been able to drive 120 - 160 km (or 75 - 100 miles) once their low fuel light came on and others have said that the lower than expected range on the guessometer is by design by Toyota as its bad for hybrid engine to run out of gas.

Are those with the gas only engine experiencing the same issue?

The more we can have folks add to this discussion the better informed we'll all be.
The most I’ve been able to put in is 13.3 gallons.
 
We just purchased a Grand Highlander Hybrid and are having this same issue. I explained things to the dealer and was told that the engine has to "get set up" so it is reading correctly. So basically, I have to take their word for it that what I was sold, is actually what I received. We wouldn't have purchased a car that has a 12.5 gallon tank. So... What are my rights here? Can I return it? Can we claim false advertising?
 
We just purchased a Grand Highlander Hybrid and are having this same issue. I explained things to the dealer and was told that the engine has to "get set up" so it is reading correctly. So basically, I have to take their word for it that what I was sold, is actually what I received. We wouldn't have purchased a car that has a 12.5 gallon tank. So... What are my rights here? Can I return it? Can we claim false advertising?
The moment that car was registered in your name and you rolled it out of the dealership it became a used vehicle and depreciated in value about 10%. It's not something you can just return because you aren't satisfied. You have whatever rights your state lemon law affords you, but I doubt this would qualify as it wouldn't be considered a serious defect that keeps you from driving the vehicle or affects safety. You have the right to hire an attorney to sue the dealership and Toyota for whatever cause of action you and your attorney felt would work, but that would get very expensive very quickly. Your only real option is to go trade it in for something else and bite the bullet for the financial hit you will take. Only you can determine whether your dissatisfaction is worth the expense of trading it in, but it would certainly be less costly than the first retainer check you'd write to an attorney.
 
The moment that car was registered in your name and you rolled it out of the dealership it became a used vehicle and depreciated in value about 10%. It's not something you can just return because you aren't satisfied. You have whatever rights your state lemon law affords you, but I doubt this would qualify as it wouldn't be considered a serious defect that keeps you from driving the vehicle or affects safety. You have the right to hire an attorney to sue the dealership and Toyota for whatever cause of action you and your attorney felt would work, but that would get very expensive very quickly. Your only real option is to go trade it in for something else and bite the bullet for the financial hit you will take. Only you can determine whether your dissatisfaction is worth the expense of trading it in, but it would certainly be less costly than the first retainer check you'd write to an attorney.
We love the car otherwise. But wouldn't have purchased it if the fuel tank was truly a 12.5 gallon tank. Nevertheless, it sounds like it may not actually be a 12.5 gallon tank and may just read that way. It should be more clear though. Bummer. Thanks for replying.
 
We love the car otherwise. But wouldn't have purchased it if the fuel tank was truly a 12.5 gallon tank. Nevertheless, it sounds like it may not actually be a 12.5 gallon tank and may just read that way. It should be more clear though. Bummer. Thanks for replying.
It's actually a 17.2 gallon tank with a very large cushion on the distance to empty calculation. I always fill up when I reach 1/4 tank regardless of what the DTE says. I think you'll find it's no more than an annoyance. Don't let it spoil an otherwise good experience :)
 
We just purchased a Grand Highlander Hybrid and are having this same issue. I explained things to the dealer and was told that the engine has to "get set up" so it is reading correctly. So basically, I have to take their word for it that what I was sold, is actually what I received. We wouldn't have purchased a car that has a 12.5 gallon tank. So... What are my rights here? Can I return it? Can we claim false advertising?
I think the "get set up" statement might actually be true. I'm finding that the DTE after each gas refill is increasing. If i remember correctly, when I just got the GHHL, the DTE was around 450 miles after each gas refill and has slowly increased after filling up the gas tank each time. In the last 3 fills, it has increased to 500, 516, and 520. I think it's getting closer and closer to the rea-world DTE. My last fill up was almost 15 gallons and I ran it until maybe a couple miles after the DTE went below zero, so just a little over 2 gallons left in the tank when DTE just hit below zero, which I think is reasonable. My take is that the car is self-learning and self-calibrating each time gas is filled up. Would be nice if it came out of factory correctly calibrated, but I can live with it that the DTE number has self-adjusted to my real world driving MPG after about 4 months.
 
I just got my GHHL on Friday last week, and only have a total of 201 miles on it. But my DTE is reading 302 right now for a total of 503 miles. So if that is anywhere near accurate, I should be getting what I was expecting.
 
I think the "get set up" statement might actually be true. I'm finding that the DTE after each gas refill is increasing. If i remember correctly, when I just got the GHHL, the DTE was around 450 miles after each gas refill and has slowly increased after filling up the gas tank each time. In the last 3 fills, it has increased to 500, 516, and 520. I think it's getting closer and closer to the rea-world DTE. My last fill up was almost 15 gallons and I ran it until maybe a couple miles after the DTE went below zero, so just a little over 2 gallons left in the tank when DTE just hit below zero, which I think is reasonable. My take is that the car is self-learning and self-calibrating each time gas is filled up. Would be nice if it came out of factory correctly calibrated, but I can live with it that the DTE number has self-adjusted to my real world driving MPG after about 4 months.
How did you fill it, was the fuel nozzle wide open or slow, did you fill past the shutoff? I’ve had my Limited only 3weeks , so I’m trying to get a feel for it.
 
How did you fill it, was the fuel nozzle wide open or slow, did you fill past the shutoff? I’ve had my Limited only 3weeks , so I’m trying to get a feel for it.
I fill it with the fuel nozzle at full. I'll top up 3 times after the 1st click. I did the same with my old 2010 Highlander Hybrid to get the tank to full. When I used to not top up, the gas gauge wouldn't even get to full. So, it's become a habit to always top up a few times on the GHHL too.
 
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