2025 Toyota Grand Highlander fuel system problems

Filed Oct 15, 2026 · Fuel system · IL

The vehicle exhibits abnormal fuel system behavior. When the vehicle reaches a low fuel condition (approximately 40–50 miles to empty), the fuel tank only accepts about 12 gallons, even though the listed tank capacity is 17.2 gallons. After refueling, the fuel gauge displays FULL and the “Distance to Empty” reading jumps to over 360 miles, which is inconsistent with the amount of fuel added. A Toyota dealer documented this behavior on a repair order, stating that the tank accepted only 12 gallons from a low fuel condition and immediately displayed a range of 363 miles. A second repair order states that the fuel system was inspected and that the tank supposedly has a “3–5 gallon reserve,” but no technical documentation was provided to support this claim. Toyota’s customer support later provided a written response stating only that mathematically 3–5 gallons must have been in the tank, without offering any engineering explanation for why the gauge reads FULL or why the vehicle reports an inflated driving range after adding only 12 gallons. The dealer also provided documentation explaining the issue using online forums and social media posts rather than Toyota engineering documentation. Safety concern: Because the gauge displays FULL and the vehicle reports a high range when the tank has not actually been filled to capacity, the vehicle may be operating with significantly less fuel than indicated. This creates a risk of unexpected fuel starvation, hybrid system shutdown, and loss of propulsion if the vehicle runs out of fuel while the driver believes adequate range remains. Supporting documents include dealer repair orders, Toyota’s written response, a dealer explanatory response, and confirmation that the issue was escalated internally.

Filed Sep 14, 2026 · Fuel system · AZ

Our 2025 Toyota Grand Highlander Platinum repeatedly produces a strong gasoline odor and visibly observable vapor under hot-weather/hot-soak conditions. The condition has been observed by dealership personnel. There is footage from us and the dealership. The manufacturer has characterized the condition as normal, but has not provided a technical explanation identifying the source of the vapor or documentation establishing that visible gasoline vapor is within design/safety specifications. I am reporting this because I am concerned that waiting until an injury, fire, or other serious incident occurs before addressing the condition is inappropriate. I am asking the federal safety agency to determine whether this represents a safety-related defect or a broader safety issue affecting other Toyota vehicles. I am unable to upload the video, but I am willing to provide it by other means.

Filed Sep 9, 2026 · Fuel system · CA

I am experiencing a strong gasoline odor & what appear to be gas vapors coming from the gas cap/filler area of my vehicle. A daily problem. Fumes are consistently present & enter the cabin, when the air conditioning is not on recirculation mode or when doors are opened. I can see and smell it when stopped & idling & I can visually see it when driving. Toyota has already performed multiple inspections & safety checks but has been unable to identify the source. A vehicle health check found no diagnostic trouble codes. The EVAP system was pressure tested & passed w/ no leaks found. Fuel lines, fittings, injectors & the high-pressure fuel pump were also inspected & all reportedly passed. The inability to identify the source does not mean the condition does not exist—it demonstrates that the current testing has not identified the source. I should not be expected to continue transporting my family in a vehicle w/ an ongoing gas vapor concern simply because standard diagnostic testing has not located the problem. My greatest fear is that an unidentified source of gas vapors could create a serious fire or explosion hazard. Gas vapors are highly volatile & when present in sufficient concentrations & exposed to an ignition source, can ignite. I continue to smell gasoline & detect what appear to be vapors around & inside the vehicle every day, I am afraid to drive it & constantly worry about the possibility of a fire or explosion while my children are inside. Breathing in these fumes are extremely toxic. My greatest concern is for my three children. Two are under the age of [XXX] & cannot communicate whether they are experiencing headaches, dizziness, nausea, respiratory irritation, or other symptoms. My [XXX] rides in the third row, closest to the rear area where I am detecting these vapors. I purchased this vehicle to safely transport my children. Instead, I no longer feel safe transporting my family in it. This is an ongoing, unresolved safety concern. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOI

Filed Aug 26, 2026 · Fuel system · AZ

I have noticed on several separate occasions a strong gas odor coming from my 2025 Toyota Grand Highlander after I have completed a drive. This has been intermittent, however, yesterday on XXX, the gasoline odor was so strong after I parked my vehicle in my garage, that it quickly filled the garage with an overwhelming odor. My son urgently came to get me when he stepped into the garage and realized how strong the fumes were. We had to open the garage to air it out. I called the Larry Miller Peoria Toyota dealership immediately and had my vehicle inspected the following day on XXX. I was informed by the service advisor that Toyota receives numerous complaints daily about this very issue with the newer model Highlanders, Grand Highlanders, Tacomas, and 4Runners. I insisted that my vehicle be inspected. The report stated that they were unable to duplicate the condition. The report states that no leaks were found with the evap system. The report also states that whe outside temps are extremely high, fuel inside the tank expands and creates additional vapor. I was assured by the service team that the fuel tank is operating correctly, despite the overwhelming fuel vapors that are intermittently emitted. I have lived in [XXX] my entire life and I have never encountered this issue with any vehicle that I have owned. These fumes are toxic and I am very concerned about my family being exposed and our safety/wellbeing. I have installed a carbon monoxide monitor in my garage. I have also filed a formal complaint at the Corporate level within Toyota and am awaiting a response. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jul 25, 2026 · Fuel system · AZ

The component that was available for inspection was our gas tank. It provided a profuse smell of fumes coming out of the tank and/or exhaust. You could also see vapors coming out of the gas tank when driving. The fumes alone are extremely toxic and extreme levels. The safety of me, my two young children and husband is all at risk. The smell of the gas and the view of the vapors from the gas tank puts the vehicle at an extreme fire risk. The smell of the fumes out it at a toxic inhalant risk - especially having two young children. This has caused great fear within me and the safety of my children is at extreme risk. No. I have taken the vehicle to the dealer 2-3 times, advised each time there is no issue with the vehicle. However, the smell of the gasoline has happened 6-8 times since purchasing the vehicle in May 2025. The vehicle has only been inspected by the dealer. Unsure who else to bring it to. The first time it was towed because the smell of the gas was in the cabin of the vehicle and I did not feel safe having my two small children in it with the extreme gas smell. No, no warning lamps. No indicators. The first time it happened I was alone with my two small children and the only indicator was the vapors coming out of the tank that were visible, and the extreme smell of the gasoline when I would roll my window down.

Filed Jul 22, 2026 · Acceleration, Fuel system · CA

After a complete stop at a stop sign there is hesitation/stalling when trying to accelerate. Sometimes the hesitation is several seconds and then the engine kicks in and lurches forward. Couple times this has been a safety issue as it happens when I’m trying to pull out on a busy road. The delay/hesitation has caused me to almost get hit a few times. There are no lights or warning messages when this happens. It happens a multiple times a week especially during hot weather when AC is on full (LO temp setting and maximum fan) and is usually during the first few minutes of operation usually at the same stop signs on my route to pickup my kids after the car has been sitting unused overnight. I also notice that the hybrid battery indicator is usually always at 3 bars. Dealership hasn’t been able to reproduce as it's a very specific scenario (not driving/in garage overnight and short drive). Instead they went and applied T-SB-0040-25 but this hesitation is still happening after the software update. This needs to be handled like a safety issue/recall worthy with a complete fix! Not just some drivability issue that only gets applied if we ask about specific T-SBs.

Filed Jul 14, 2026 · Electrical, Engine · NM

Radiator issue summer of 2025, when in back to back traffic at low speeds my vehicle overheated at a stand still took vehicle in to dealership with no real answers. The following summer 2026 same scenario but the engine was smoking. Took into dealership and they stated the connection for the radiator fan was disconnected which meant it was not colling the engine. A month later the AC is blowing hot air when AC is set to the coolest setting, scheduled another appt with dealership likely another radiator issue. Fuel gauge inaccuracy. Manual states 17 gallon tank capacity but my car states empty and can only fill the tank with 14 to 15 gallons. Dealership had no help and stated it does that to protect the hybrid engine. Transmission shifting issues, in the summer hotter temperatures I notice at times the transmission has difficulty shifting in lower gears and really revs up the RPMs to shift sometimes. At times the the transmission shift is jerky or harsh when going speeds form 20- 40 mph.

Filed May 19, 2026 · Engine, Fuel system · NY

On multiple occasions (four) my 2025 Toyota Grand Highlander Hybrid Max has failed to accelerate when I push the gas pedal. Once in traffic, which was extremely scary and a huge hazard. I have contacted the dealership about this issue and have not heard back from them. It has been almost 2 weeks. No warming lamps turned on and this issue lasted about 15 seconds each time. I press the gas, the car does not respond other than an audible RPM raising sound.

Filed Jan 29, 2026 · Fuel system · CA

The entire life of the car from initial purchase the fuel gauge is incorrect. The car has a 17 gallon gas tank and the fuel gauge is calibrated to around 13 gallons. The car thinks it is out of gas around 13 gallons when there is actually 4 more gallons left.

Filed Aug 21, 2025 · Fuel system · VA

The car only accepts 11-13 gallons of gas when refueling an empty tank despite the advertised 17.2 gallon capacity. I believe this is a fuel gauge or DTE system problem. I’ve seen many many similiar complaints on the forums. Fuel gauge issue could leave drivers stranded on the road.