NHTSA Complaint #11450021 — 2021 TOYOTA HIGHLANDER

FUEL/PROPULSION SYSTEM issue reported to NHTSA

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Complaint Details

ODI Number 11450021
Vehicle 2021 TOYOTA HIGHLANDER
Component FUEL/PROPULSION SYSTEM
Date of Incident
Date Filed
Mileage N/A miles
Crash No
Fire No
Injuries 0
Deaths 0
Vehicle Towed No
State MD

Consumer Description

My concern has to do with an inability to completely fill the gas tank in my 2021Toyota Highlander Hybrid XLE (AWD), and the gas tank capacity has worsened over time. I purchased the vehicle new from a Toyota dealer in Maryland in April 2021. Initially, I could fill the gas tank to almost full per the gas gauge. Over time, the amount of gas the tank can hold has decreased. As of early 2022, I can only fill the tank to just above 3/4 full per the gas gauge. Please note that when filling the tank at a gas station, I always stop filling when the gas pump shutoff switch activates (1st click) - I never "top off" the tank. It is certainly annoying to not get anywhere close to advertised range of the vehicle (the vehicle display shows a range just over 400 miles/tank versus an expected 600+ miles). However, my main concern is safety-related - I don’t trust my fuel gauge and fuel monitoring system, and as a result I fill the tank whenever I approach 1/2 full per the gas gauge. This is so I don't inadvertently run out of fuel. In Sept 2021, I took my vehicle to the Toyota dealer where I purchased it to report this fuel tank issue. The dealer's service department "verified [customer's] concern that the fuel pup clicks off before gas tank was full." The dealer also "created a TAS Case #xxx and with the information give was informed there is an active investigation by Toyota on this concern and there is no repair available at this time." Since then, the dealer has not reported anything new from Toyota USA (they said "we'll hear about any fix the day before you do.."). I called Toyota USA last Fall and also got no indication on an impeding fix. Bottom line - Toyota USA has been silent on the matter, although there is certainly lots of online chatter from other owners and mention of a lawsuit against Toyota. I am wondering if this issue is similar to what was noted (and finally fixed?) for Toyota's late model RAV4 hybrid vehicles.

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