2024 Toyota Grand Highlander Fuel System Problems

Mileage when the problem started

Owner reports

Selected complaints filed with NHTSA by 2024 Toyota Grand Highlander owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2024 Toyota Grand Highlander. The contact stated that while driving at an undisclosed speed, there was an abnormally strong gasoline odor inside the cabin of the vehicle. The contact believed that the odor was caused by a fuel leak. The vehicle was taken to a dealer, where it was diagnosed with an evaporator filter failure, and it was determined that a fuel leak was not the cause of the odor. The dealer stated that the vehicle did not require a repair and could still be driven with the odor inside the vehicle. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 45,000.

The contact owns a 2024 Toyota Grand Highlander. The contact was unable to fill the fuel tank completely. The contact stated that the fuel tank had a 17-gallon capacity; however, the contact was only able to get more than 10 gallons into the tank. Additionally, the contact stated that the Auto START/STOP feature was not functioning as needed. The contact had taken the vehicle to a local dealer, who was unable to determine the cause of the failure. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was 16,455.

Toyota is having issues filling up the tank as the specs says (Owners manual book). According to the Owners manual book, the Gas tank of these vehicles are 17.2 Gallons and 2.6 of those are saved for the reserved. In theory, we should have 14.6 Gallons to fill-up as soon as we see the "Empty sign" on the vehicles. Now, the thing is that even after this happens, we can only fill-out up to 11.5 gallons. I have tried several times, saving the history on FUELLY, and its always the same. I have asked the dealership and they don't know what to do. …

I am submitting this complaint regarding a catalytic converter failure on my vehicle and the manufacturer's refusal to honor the warranty. My vehicle is a Toyota that is approximately two years old and currently has about 31,000 miles. The catalytic converter has failed well before what would normally be expected for this component. When I brought the vehicle to the dealership for repair under warranty, Toyota declined to cover the repair. They stated the failure was due to "contaminated fuel," but they did not provide any evidence or test results showing that contaminated fuel was present in the vehicle. I have not been provided with documentation, diagnostic data, or fuel analysis supporting this claim. The denial appears to be based on assumption rather than proof. …

I own a 2024 Toyota Grand Highlander Hybrid MAX Platinum, purchased brand new in February 2024 and now with approximately 30,400 miles. Since the first few weeks, the vehicle has had an ongoing fuel tank/range issue. The fuel tank is rated at approximately 17 gallons, but the gas pump consistently shuts off after only 10-12 gallons, even when the vehicle indicates 0 miles to empty. It accepts approximately the same amount whether I refuel with 80, 20, or 0 miles remaining. After filling, the vehicle reports the tank as full and but generally shows only 270-290 miles of estimated range. The actual miles driven before requiring fill up is 230-250 miles. Toyota issued T-SB-0060-25 (Low Fuel Warning Light Logic Enhancement), which a Toyota dealer reluctantly performed on my vehicle. …

The incidents most often occur when I try to accelerate after vehicle is stopped at an intersection. The car hesitates during acceleration regardless of how much I push the gas. Once it starts to go, it feels as though the car can't shift from 1st to 2nd gear. The RPMs get up 4500 while the car is going 25-40 mph and remain there for a few seconds up to ~20 seconds. I am fearful of getting t-boned when my car hesitates while turning at an intersection, going through an intersection or pulling out from a parking lot. I have been stuck in several intersections when traffic was coming toward me, but thankfully those cars were able to avoid hitting me. I have reported the problem every time I take the car to the dealer for a service. The problem has been happening since I purchased the car in November 2024 and occurs randomly--sometimes every couple of months, sometimes days in a row. …

Since purchasing this vehicle when I have driven the vehicle and come home the vehicle smells of gas vapor/fumes. It's so bad the entire garage will fill with the vapor. Im afraid the garage will explode. I have to leave the vehicle parked outside for several hours until the smell is gone. This is a known issue for this car as others have complained about the same thing. Dealership has confirmed it is a known problem. They tried o tell me the first time I took it in that it was due to extreme heat in Las Vegas. I explained that our other vehicle and our friends vehicles don't do this and that is merely an excuse. After researching online I found that several other others in other states have the dame issue. When I recently took the vehicle in for software/radio issue as well as the gas vapor they did confirm it is a known issue. …

I have a 2024 Grand Highlander and when I get to empty the most I can put in it is 10 1/2 gallons of gas. Toyota said I had a 17.2 gallon gas tank. I've called Toyota. They set up a appointment. They were going to pull the gas tank and check the sensor. The dealership said oh no you have a 5 gallon plus reserve in that we have the same problem with the RAV4, the problem is because on trips you have to keep stopping for gas when I get 325 to 340 miles it tells me I'm empty when I fill up it says I can go 520 to 540 miles the most I've ever been able to put in it was 12 gallons and that was going down beyond empty and driving it for another 50 miles. It doesn't make sense to have 5 gallons 6 gallons 7 gallons of gas sitting in my truck that I'm carrying that weight and not getting to use it this just doesn't seem like Toyota's way of fixing things. …

After driving over 15k miles in approximately one year, my 2024 Toyota Grand Highlander Hybrid fuel tank has never been filled with more than 12 gallons of gas, even when the Low Fuel light is on and the miles to empty are less than 10. The MPG for individual trips can be as low as 10.3 MPG; the overall average MPG has been 21 MPG or less. The advertised fuel tank size is 17 gallons and the MPG is 26/27. The Toyota dealership said that there are 3-5 gallons remaining in the tank when there are as few as 5 miles to empty. Actual miles to a tank are around 280-300 when driven in Eco mode; advertised is 450 miles when driven normally. Inaccurate fuel level sensing is a safety issue. 10.3 MPG for a Hybrid that is advertised to get 27 MPG is false advertising. This is a known issue since at least November 2023, as evidenced by the Manufacturer Communication Tech Tip T-TT-0742-23 on NHTSA.GOV.

Published 2024 Toyota Hybrid Grand Highlander (TGH) specifications, the TGH owners manual and dealer information provided indicated the vehicle has a 17.2 gallon fuel tank. However, the most fuel I am able to get in the tank is between 11 and 11.5 gallons. I've had the vehicle in to fix the defect on three occasions; 2023-11-27, 2024-3-11, & 2024-8-13 to no avail. On the second service, Toyota's technician said the tank had 16.8 gallons remaining when I picked it up, I had filled it the previous day and driven approximately 15 miles. Once the gauge showed near empty with only a few miles left of fuel, I filled the tank and was only able to get 11.4 gallons in the tank. There appears to be six gallons of fuel that I am carrying in the tank that the fuel system cannot access. I have searched on-line and found that a number of other TGH owners are experiencing a similar defect.

Fuel System complaints in other Grand Highlander years