[Jmotley]

Have any other 2020 Highlander Hybrid (AWD) owners having issues with filling the fuel tank all the way or the DTE display showing much less than it should?

When I took delivery of my 2020 Highlander Hybrid last month I was concerned that the "Distance to Empty" display read only 420 miles. I asked the salesman if this was right and she confirmed that the fuel capacity of the vehicle was 17.1 gallons and the MPG is rated at 35 so the range should be about 600 miles. Then she said that it might take a while for the computer to reset and show the correct DTE.

I've only driven the vehicle 725 miles since I got it due to Covid-19 restrictions, and while it's averaging 35.6 miles per gallon (mostly ECO mode), the vehicle only shows about 420 miles DTE when refueled. This week I specifically waited for the low fuel light to go on and drove a few miles past just for good measure. I went to the gas station and only could pump 12 gallons before the pump shut off. I tried topping off the tank and eeked 12.5 gallons into the tank and showed DTE of 445 miles – far less than the 609 miles I expected.

I took the vehicle back to the dealership and explained the problem. They checked for error codes, software updates, recalls and TSBs and found nothing. They noted that that were no issues. I called Toyota corporate and was told the same thing - no issues reported.

I did some research (“Google”) and found that 2019/2020 RAV4 Hybrids with the same new “saddle” tank design are having the same problem I’m experiencing. Apparently, the new tank design is required to accommodate the hybrid drivetrain and won’t fill all the way. RAV4 owners can fill about 9 to 10 gallons of the 14.5 gallon tank – pretty consistent with what I’m getting with 12 gallons of the 17 gallon tank capacity.

I’m pretty sure there’s a design defect in the Highlander Hybrid fuel tank preventing the last five gallons of gas being pumped thus cheating me out of 180 miles of range.

While Toyota has acknowledged an issue with the RAV4 and are working on a fix, they haven’t acknowledged a problem with the Highlander yet. I guess I might have to join the RAV4 class action lawsuit in order to get satisfaction?

Toyota Faces Class Action Lawsuit for Faulty RAV4 Hybrid Fuel Tanks
Toyota offers interim fix for Rav4 Hybrid gas tank concerns

Thoughts?

 

[Jmotley]

Did you buy the vehicle because it can go 600 miles between fill ups, or were there other reasons? I know my bladder wouldn't last for even 400 miles without a stop, let alone 600 miles. 😀

In all honesty, what will it take for you to "get satisfaction"?

Just curious.

The only reason I paid a premium for an XLE Hybrid was for better gas mileage and longer range. I could have gotten a gas Limited for just a little more since they aren't dealing much on hybrids . . .

 

[Jmotley]

😄. Perhaps anyone who isn't satisfied with their mpg should join this lawsuit. I am pretty sure Toyota will enjoy this.

Toyota bought back my 2019 rav4 hybrid exactly for that issue. The tank didn't took entire 14.5 gallons, i was short by about 3 gallons and was getting under 300 miles on tank. I didn't join lawsuit to get satisfaction just submitted NCDS complaint back in January and recently got the check for it. So owned it free for a year basically.

I think I'll file a complaint since neither the dealer nor Toyota corporate were very helpful or encouraging. I'm guessing this vehicle's only now showing up in the market that there's not much field experience yet . . .

One aspect that is different from the RAV4 is - at least with my Highlander Hybrid - is that after a fill up the gas gauge reads full and stays there for at least 100 miles. RAV4 owners were complaining their gauge wouldn't read full. But I also get the reduced DTE after a fill up even after averaging over 40 mpg and not getting anywhere near a 600 mile estimate. I'm currently running the tank down until the low fuel light comes on to see how much fuel it will take on a fill up but suspect I'll get the same results as Jmotley.

EDIT - current tank is reading between 1/4/and 1/2. I've traveled 410 miles and DTE is listed at about 120 miles but has been going down slower that actual miles traveled as my tank average is at about 42.5 mpg for that 410 miles. Should get about 550 before fuel light come on (?)

Yes, my tank reads full afterwards. DTE is 420 though. I did notice that the last 10o miles of DTE went down very slowly. I'll need to monitor this more closely.

Low fuel light comes on with 2.6 gallons left in tank so if you got 12.5 gallons in you were 2 gallons short of being totally full. So 12.5 gallons at 36.5 mpg is 445 miles until the light comes on again so using that criteria it seems right. The question is why you couldn't get the last two gallons in. If you could that would give a range of 516 miles for the 14.5 gallons until the light comes on.

Actually, the Highlander Hybrid is supposed to be 17.1 gallons capacity so I'm 4.6 gallons short or 168 miles short.

 

[Jmotley]

Crossposted from Highlander 4th Generation (2020+) forum

Have any other 2020 Highlander Hybrid (AWD) owners having issues with filling the fuel tank all the way or the DTE display showing much less than it should?

When I took delivery of my 2020 Highlander Hybrid last month I was concerned that the "Distance to Empty" display read only 420 miles. I asked the salesman if this was right and she confirmed that the fuel capacity of the vehicle was 17.1 gallons and the MPG is rated at 35 so the range should be about 600 miles. Then she said that it might take a while for the computer to reset and show the correct DTE.

I've only driven the vehicle 725 miles since I got it due to Covid-19 restrictions, and while it's averaging 35.6 miles per gallon (mostly ECO mode), the vehicle only shows about 420 miles DTE when refueled. This week I specifically waited for the low fuel light to go on and drove a few miles past just for good measure. I went to the gas station and only could pump 12 gallons before the pump shut off. I tried topping off the tank and eeked 12.5 gallons into the tank and showed DTE of 445 miles – far less than the 609 miles I expected.

I took the vehicle back to the dealership and explained the problem. They checked for error codes, software updates, recalls and TSBs and found nothing. They noted that that were no issues. I called Toyota corporate and was told the same thing - no issues reported.

I did some research (“Google”) and found that 2019/2020 RAV4 Hybrids with the same new “saddle” tank design are having the same problem I’m experiencing. Apparently, the new tank design is required to accommodate the hybrid drivetrain and won’t fill all the way. RAV4 owners can fill about 9 to 10 gallons of the 14.5 gallon tank – pretty consistent with what I’m getting with 12 gallons of the 17 gallon tank capacity.

I’m pretty sure there’s a design defect in the Highlander Hybrid fuel tank preventing the last five gallons of gas being pumped thus cheating me out of 180 miles of range.

While Toyota has acknowledged an issue with the RAV4 and are working on a fix, they haven’t acknowledged a problem with the Highlander yet. I guess I might have to join the RAV4 class action lawsuit in order to get satisfaction?

Toyota Faces Class Action Lawsuit for Faulty RAV4 Hybrid Fuel Tanks
Toyota offers interim fix for Rav4 Hybrid gas tank concerns

Thoughts?

 

[Jmotley]

Wow. I'll need to check the Connected Services app after my next fill up. Makes sense . . .
BTW, I have the same color. It's a beautiful vehicle - inside and out. It's a shame we're having this issue.

I might have discovered some evidence that the HH has been tweaked by Toyota to hide the fact that it does share a similar problem as the RAV4 with filling the gas tank. While the RAV4 owners couldn't get the gas gauge to read full and the Highlander's gauge will read full even though the tank doesn't seem to take the correct amount of fuel to do this it could very well be that they adjusted the Highlander's software to hide the problem and the reason it takes over 100 miles for the needle to move off the "F".

It would appear that while they could adjust the gauge on the dash to show full they couldn't adjust the software on their Connected Services App to show a full tank. Looking at my Connected Services App after only driving five miles after filling up it shows the fuel level as being at about 7/8 of a tank which could be more accurate.

Sneaky engineers.

View attachment 298318

 

[Jmotley]

That is exactly my experience. I asked the sales rep and she agreed that it should have been more like 600 DTE . . .

For what it's worth, when I drove off the lot, I had 9 on the odo, 415 DTE, and the gauge reading over full. Thought the 415 was low but never thought much about it until now. View attachment 298372

 

[Jmotley]

Thanks for the video! That’s exactly my experience. I’ll vide9 my next tank fill - if I ever get a chance to drive anywhere that is.

I'm having the same issue. I called the Toyota Customer Experience Line and was told to bring it into the dealer. It's frustrating being lied to by Toyota when your dropping over $40K for a new car.
My experience is highlighted in a youtube video I made of the problem this week:

 

[Jmotley]

I'm not exactly sure how relevant this article is but I think the 2020 Highlander Hybrid has the same issue.

Toyota RAV4 Hybrid Gas Tank Issue: Toyota’s Response | Torque News

Learn more details about the 2019 and 2020 RAV4 Hybrid fuel tank situation, and how Toyota is addressing it.

www.torquenews.com