Tank Assembly problems of the 2003 Toyota Highlander

Vehicle which was out of warranty was parked in driveway and was observed during early morning hours to be leaking fuel from the bottom of the fuel tank. Vehicle was towed to the dealer who reported that the roll-over ball (safety feature in a roll-over crash) had activated and had floated to the top of the fuel filler neck forcing fuel into the charcoal canister. The fuel tank had been filled several days previously. Dealer estimated repairs to be $1500 for a new tank, canister, and other parts. Fortunately, the district rep for Toyota intervened and paid for all parts and half of labor at warranty rates. Vehicle owner was responsible for only $248. 50.

While driving. A loud noise was heard as if the vehicle had ran over something large in the road. The consumer noticed a liquid spraying out from the vehicle, once he pulled over, the vehicle was towed to the dealership and the consumer was informed a hole was in the gas tank. However, one month later the same loud noise was heard and the consumer discovered the gas tank had a deep indentation in it. The consumer requested reimbursement for the gas tank.