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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I do 1 top up after the first click and get ~½ gallon. How much do you get on the 2nd and 3rd top up?
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The "fuel light" came on with 13 DTE showing.
(3rd) tank filled with 9 DTE showing (had traveled 452 miles), fuel nozzle clicked off at 14.2 gallons, clicked nozzle couple more times to assure tank was full, total 14.538 gallons taken.
Fuel guage showed full and 472 DTE (36.3 aver mpg).
See what happens, will run tank down till "fuel light" comes on.
(3rd) tank filled with 9 DTE showing (had traveled 452 miles), fuel nozzle clicked off at 14.2 gallons, clicked nozzle couple more times to assure tank was full, total 14.538 gallons taken.
Fuel guage showed full and 472 DTE (36.3 aver mpg).
See what happens, will run tank down till "fuel light" comes on.
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No cabin boom.
Hood rattle tho not noticeable unless you look for it!
Interesting. My last two fills were 12.4 g with 24 DTE & 12.6 with 50 DTE (probably an under fill based on estimated vs actual MPG). Both fills were to the second "click".
I let my dealership know about the fuel issue in May. They had me bring it in twice, the first no idea what they did, but they did confirm it is an issue, and then ordered the fuel pump/tank. They had me drive it until close to empty and bring it in. I did ask them to measure the remaining fuel, but they could not. That all was on the 5/17, thus the weird data. Mathematically there is between 3-5 gallons unaccounted for. After a fill up it seems to always say we have 390 miles to empty. The most I've ever been able to put into the tank was 11.472 gallons. I let them know
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That is so strange. I did my first fill up with the DTE at around 50 miles. I put in 13.8 gallons. I did run the pump twice after original shutoff which is not recommended. Not sure about the fuel mileage estimate. Combined usage along with miles to empty is 475?
I just filled up my all gas XLE - 20 mi on DTE, 1/8 on fuel gauge. 14.2 gallons to first click and left it there. 315 miles traveled, 22.2 MPG according to the Fuelly app. Just about all city driving. Looks like the fill-up problem is a problem I avoided 
It seems to be an issue only with the GH Hybrids, not the gas onlyI just filled up my all gas XLE - 20 mi on DTE, 1/8 on fuel gauge. 14.2 gallons to first click and left it there. 315 miles traveled, 22.2 MPG according to the Fuelly app. Just about all city driving. Looks like the fill-up problem is a problem I avoided
Have GHHL.
Today DTE showed 27 when low fuel light came on & fuel guage showed less then 1/8 tank.
Did a fill up with DTE at 20, tripometer showed 536 miles traveled on that tank.
Total Aver MPG at 39.
Fuel nozzle kicked off at 12 gal, did 1 more click + rounded off to next dollar for 12.26 gal fill-up.
Vehicle was turned off during fill-up, when started, DTE calculation showed 504, tank guage full.
Doesn't appear that the 17.2 gal capacity tank (2.5 gal reserve) is calibrated in to fuel guage or DTE number.
The DTE appears to be constantly recalculated based on the distance traveled under both gas and battery power, amount of gas in tank and total average mpg.
Today DTE showed 27 when low fuel light came on & fuel guage showed less then 1/8 tank.
Did a fill up with DTE at 20, tripometer showed 536 miles traveled on that tank.
Total Aver MPG at 39.
Fuel nozzle kicked off at 12 gal, did 1 more click + rounded off to next dollar for 12.26 gal fill-up.
Vehicle was turned off during fill-up, when started, DTE calculation showed 504, tank guage full.
Doesn't appear that the 17.2 gal capacity tank (2.5 gal reserve) is calibrated in to fuel guage or DTE number.
The DTE appears to be constantly recalculated based on the distance traveled under both gas and battery power, amount of gas in tank and total average mpg.
Hi, I am new to forum, didn’t realize so many GH owners have the same gas tank fill problem. First off the Low Fuel Warning Light (LFWL) comes on @ 2.5 gal remaining in tank (ref OM page 522). The LFWL system is separate from fuel gauge and has permanent height inlet and sensor that actuates when tank at 2.5 gal remaining. The fuel gage system has a floating pickup that rise and falls with fuel in tank. I wait until warning light comes on and SetTrip B to 0 miles. My Hybrid Max has a 17.2 gal tank. LFWL “ON” should allow 14.7 gal fill. 25 miles after light “ON” I can only add 12.9 nine gal, using 3 click-offs on gas pump. If low warning light accurate then tank only holds about 14.7 usable gals. Has anyone had a dealer correct their gas fill/Tank capacity Issue ? Going to dealer soon for 6 months service. Thanks PeteH
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Bad News: I'm having the same issue with gas gauge. I contacted Toyota Corporation/Manufactuer and I was told take it back to dealer to see if they will buy back the vehicle. What an answer from Manfactuer! I bought GHHL because of the 17.2 fuel capacity and fuel economy. I'm going to predict recall on all 2024 GH for guel gauge issue. If not, lawsuits will be linning up to be filed.
While I can certainly understand your being upset over this issue, I honestly don't see people lining up to litigate this. What's your cause of action and damages? No attorney is going to take a case like this on contingency (if at all), which means writing a rather sizeable check as a retainer to get this started. Plus, Toyota North America has a team of attorneys who will just motion and discovery you to death until you run out of money. You will probably end up spending more in legal fees than the car cost you by the time you are done. Sure, if you are successful you can be awarded legal fees, but you will have to front the money in the meantime, and litigation like this can take quite a while. So while I understand your frustration, I'd suggest waiting until Toyota acknowledges the issue and comes out with a fix, or if you are really that dissatisfied, trade your vehicle in once the stop sale is lifted and there is fix for the airbag recall. The financial hit you will take on the trade will be a lot less expensive than hiring a lawyer to sue them.
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Manual says 17.2 standard gallons or 14.3 imperial gallons. I wonder if someone made a mistake and it isn't 14.3 gallons. That seems on par with what we can refuel. It is insane there is no clear answer on such a simple spec. What in the world is going with Toyota? They seem incompetent.
The issues with this vehicle certainly don't make one feel warm and fuzzy about Toyota's quality control as of late. The fuel fill issue, the transmission issue, and the airbag recall all start to make me think that my faith in Toyota's quality may have been misplaced this time around. I realize this is the first year of a new model and glitches are bound to happen, but damn...lol. How did IIHS pick up on the airbag issue while Toyota did not?
You want to see incompetent, call the Toyota Brand Engagement Center. Scary.
There is evidence above that the issue is with the DTE estimate, not in the actual tank capacity which would seem to be fixable with a software update or perhaps the fuel level sensor.
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What evidence? I don't mean that in a snarky way. Has anyone ran past 0 DTE? There was one post I saw where someone ran it very close but it still didn't add up to enough a fill up to calculate 17.2 with the 2.5 reserve. Another thread mention a saddle shaped tank and it not filling to capacity. The user mentioned a TSB on the matter. It's pretty sad that it is this unclear and murky. Toyota should be on this.
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What evidence? I don't mean that in a snarky way. Has anyone ran past 0 DTE? There was one post I saw where someone ran it very close but it still didn't add up to enough a fill up to calculate 17.2 with the 2.5 reserve. Another thread mention a saddle shaped tank and it not filling to capacity. The user mentioned a TSB on the matter. It's pretty sad that it is this unclear and murky. Toyota should be on this.
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What evidence? I don't mean that in a snarky way. Has anyone ran past 0 DTE? There was one post I saw where someone ran it very close but it still didn't add up to enough a fill up to calculate 17.2 with the 2.5 reserve. Another thread mention a saddle shaped tank and it not filling to capacity. The user mentioned a TSB on the matter. It's pretty sad that it is this unclear and murky. Toyota should be on this.
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