[alster]

Vehicle: 2020 Highlander hybrid model LE AWD
I just filled up at Costco, no self service in Oregon, same pump and location as last time. Both times when the pumped shut off on the low speed setting the attendant took out the nozzle. The gauge read above the full mark both times. I had 191 miles and used 4.251 gallons of reg. 87 octane (10% ethanol) for 44.93 MPG.

When filled up today the fuel tank gauge was exactly at 3/4 of a tank, so 4 X 4.251 gallons = 17.004 gallons which probably does no include reserve.

 

[alster]

Here in Oregon where I live and get my gas, Costco, it is strictly prohibited to pump your own gas in your car, only people with motorcycles are allowed. If I had the chance I would attempt to top it off after the pump clicks off on the low setting. I'm sure I could squeeze another 2 gallons or maybe more into it. At 35 MPG (EPA rating for AWD) with 15 gallons of gas you should get a comfortable 525 miles on a tank with 2 gallons still left.

 

[alster]

Vehicle: 2020 Highlander Hybrid LE / AWD

Filled up yesterday at Costco, no self service in most of Oregon. Same method, attendant placed pump on low flow setting and when it clicked off that was it remove from tank and hang up hose, no top off. Both fillups the fuel tank gauge needle was well over the "F" mark. Also mileage combined for both tanks was a 40.11 mpg. 1st tank 191 miles @ 4.251 gallons for 44.93 mpg. 2nd tank 254.7 miles @ 6.862 gallons for 37.11 mpg. 2nd tank was driving in heavy rain at times, temps in the 50's, sea level to well over 1500 foot mountain passes and interstate speed up to 72 MPH.

On the 2nd tank If I had been driving our recently sold 2010 Prius under the same speed and conditions MPG would have been somewhere around 43 MPG or so. Fuel gauge mark at 254.7 miles was a little over the half mark, tank with 191 miles needle was dead on @ the 3/4 tank mark. Gas is Costco 87 regular with 10% ethanol. Quite pleased with our HIghlander so far and I don't know of any other SUV this size that can get this type of MPG. When we go on vacation my wife and I will be driving our highlander and I am looking forward to see a 600 mile tank.

 

[alster]

Lloyd, when you filled up did you see standing gasoline at the filler neck cap? I know with our old, now sold 2010 Prius, I have put in nearly 2 gallons after the pump had shut off to the standing gas at the filler neck.

 

[alster]

Thanks Lloyd. When I get a chance to pump self serve I will see how much I can get in the tank once the nozzle kicks off on the lowest setting.

 

[alster]

I believe if there is 0 miles left a reserve of a couple of gallons of gas still remains and is usable. It would be safe to assume with a near empty gas tank on a fill up the tank would probably hold 19 gallons if filled to the top of the filler neck with standing gasoline visible. I believe it would be perhaps harmful to fill up to the filler neck in hot weather and not drive. If one fills up to standing gas visible in the filler neck and immediately drives off I don't believe that damage would immediately result.

 

[alster]

In Oregon for the most part I can not pump my own gas into our 2020 Highlander Hybrid. I have noticed the fill up from the Shell Station on Interstate Hwy 5 on our way home from vacation when filled, method was slow speed (first click) then when it clicks off no more gas in hang up the hose. The fuel gauge needle was exactly on "F". So when we got home I filled up again at Costco, same method there. The mpg gauge indicated 42.5 mpg for 103.8 highway 55-65 MPH miles for 38.66 MPG / miles divided by gallons. After the Costco fill up the fuel gauge needle was well over the "F" mark. Drove home nearly 14 miles and the needle did not move, unlike the last fill up at the Shell station. Believe me I am not complaining of getting 38.66 MPG with a 5,000 lb + vehicle (loaded with gear and my wife).

It seem that even if you use the same method to fill you will get different fuel gauge readings. Note: In Oregon the attendants and you, in small population counties where you can pump your own gas, are not allowed to top off by law.

I am quite sure if topped off to standing visible fuel at the neck the tank capacity would be well over 17.1 gallons, just my thoughts..

 

[alster]

In my initial findings on our 2020 Highlander Hybrid I had a chance to fill up, self serve in Eastern Oregon where it is allowed in small counties. When filling up on slow setting after auto click off I was able to still get in additional 4.2 gallons in the tank with standing fuel visible at the neck.

With the tank filled like that with nearly 325 miles the fuel gauge registered a hair under 3/4 tank and took 7.3 gallons to fill to standing fuel at the neck for over 44 MPG thats calculated and also displayed on the dash as well. In my opinion based on that I would have to believe the gas tank true filled capacity is closer to 20 gallons or perhaps even more.

 

[alster]

I think it would be quite possible to go 700 miles on a tank. The gas tank obviously holds a lot more than just 17 gallons.

 

[alster]

I hope Toyota does not replace it with a smaller gas tank.

 

[alster]

We should all know by now that the gas tank capacity of the 2020 Toyota Highlander Hybrid far exceeds it 17.1 gallons as stated by Toyota. I believe the true capacity is closer to 20 gallons when filled to the brim.

 

[alster]

While my wife and I were on vacation I had a chance to top off the tank of our 2020 Highlander Hybrid AWD LE. I filled up to standing fuel in the gas cap area. The pump was easy to use slowly and I recall the tank took about 4 gallons from the initial auto click off. At 125 miles the needle on the gas gauge, well above the "F" mark did not move one bit from the initial fillup. MPG gauge readout was 47.5 MPG. We then had to leave for home and hooked up our 3,000 + LB Jayco travel trailer, and even getting only 18 MPG towing the needle still stood at that level for quite a while.

 

[alster]

Here in Oregon I can not pump my own gas at Costco. I have noticed at Costco our 2020 Highlander Hybrid LE when filled up on the slowest setting kicks off well below the full mark on the gas gauge. I do know when filling up across the river in Washington State where self service is allowed after the initial click off you can easily by filling slowly add 3 -4 gallons.

 

[alster]

My wife and I have a 2020 Highlander Hybrid AWD model LE. Approaching 16,000 miles and purchased new in June 2020. I have noticed the same issue with the gas tank. Here in N/W Oregon I am not allowed to fill up myself at Costco where we get our gas. Seem like when filled up even on the low speed setting the gas tank needle always goes below the full mark indicating about 7/8 of a tank. I have in the past pumped my own gas where legal and found that when the gas pumped shut off I could still get in another 4 gallons or more into the tank by nursing it in. It seem like this is an issue that needs to be addressed by Toyota. I believe the issue has been officially been addressed by Toyota for the RAV 4 Hybrids 2019 + model year. When I take my vehicle in for another free oil change / service I will let them know of this issue.

 

[alster]

Yesterday I took our 2020 Highlander Hybrid AWD / LE model to Toyota for its second free oil change. I told the technician that the gas tank when filled even at low speed clicks off way before the full mark. He could not find any issues for this model with Toyota but was aware of the issue of the recent RAV 4 Hybrids. He documented this issue with our Highlander and will let me know how Toyota responds to my complaint.

 

[alster]

Yes, I have this problem and have since I bought it in March 2021. I would like to be able to go 600 miles instead of 400 without having to find a gas station in the remote area around me.

We also have the same problem with our 2020 Highlander Hybrid AWD model LE. I just filled it up yesterday at the lowest click and it took a little over 10 gallons. The gauge was at about 1/4. After fill up the gauge read under the full mark between 3/4 and full. I know after the initial click off you could still get at least 3 more gallons of gas in the tank but here in Oregon I am not allowed to pump my own gas in this county. I already let my local Toyota dealer of this problem and they documented it for me.

 

[alster]

We have a 2020 Highlander Hybrid AWD model LE now with 30,000 miles on the odometer. Filling up this has been a concern for me as even at the lowest fuel nozzle setting the pump kicks off and the fuel needle is between the full and 3/4 tank mark. I mentioned this to our local Toyota dealer over a year ago and he documented it for me and stated there was no info about a service bulletin for it.

Living in Oregon you are not allowed to pump your own gas only in low population counties. I had a chance to fill up and when the pump clicked off I still managed to pump nearly 4 gallons of gas until the tank was filled, a very slow operation I might add.

Thanks to this forum I found this bulletin and will be taking our Highlander Hybrid and this TSB bulletin to our Toyota Dealer Service Dept. here in Oregon.

 

[alster]

Toyota should have sent out a mailer to Highlander Hybrid owners who may have this issue. If it was not for this forum I would not have known about it. Yesterday received a voice mail from our local Toyota Dealer and they told me to contact them for my fuel tank to be replaced.

 

[alster]

2020 highland hybrid all wheel drive model LE owner. When refuelling after auto click you can still nurse in 3.5 gallons. We are having the tank replaced this month. I hope this works where the gauge will read above the full mark. Now after auto click, without adding more fuel, it reads between 3/4 and full.

 

[alster]

Yesterday we had the fuel tank replaced in our 2020 Highlander Hybrid model LE all wheel drive. I took the car in with the low fuel light on and it switched from 1 mile to refuel. Toyota techs. changed the tank and components in about 3 hours. I then took it to Costco about 1/2 mile away and fueled it on the low notch setting and it clicked it off at 13.906 gallons. The fuel gauge now read well over the full mark, first time this has happened. So this would mean even though the refuel message was on I still had 3 gallons of fuel still left in the tank being that its capacity is 17.1 gallons.

Before that the same method the fuel gauge would read between 3/4 and the full mark or so. No charge from Toyota, as the service writer told me that if I had to pay it would be about $1,600.00 as the fuel tank alone was nearly $900.00