I purchased a 2020 Highlander 2 weeks ago and have the same problem. The first time I filled up the tank only showed 3/4 tank. Kept topping it off until I got it to full. The DTE shows that I only hold 12 gallons. I am taking it to Dealership this week for evaluation. The Service person said he didn't know of such problems.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