How much volume of fuel does an 18.5 gallon 3rd-gen 4Runner fuel tank hold?

It's rare that you fill a bone-dry fuel tank, but I happened to have one to test. Lucky me!
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In all tests below, the vehicle was on a flat concrete pad and I left the ignition at the second position for at least five (or more) minutes for the fuel gauge reading to stabilize. I filled the gas cans myself that same day, taking care to ensure the Costco pump read 5.0(something) gallons for each gas jug.
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Since I was initially mouth siphoning, and since the suction kept breaking, it took hours of elapsed time to get the first 11.0 gallons out of the tank (which had initially read 3/4 of a tank).
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I'm pretty good at siphoning, but even I found it hard to not burp up gas when I used my beer carbonation hose, which was 12 feet long, which kept breaking suction so I had to suck it up, so to speak, if I ever wanted to finish the job. Every time the 12-foot hose broke suction, I rerouted it until I could get no more gas out by suction.
hose.jpg


With 2-1/2 gallons still left in the tank, the fuel gauge already read a hair below empty.
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Concluding that siphoning will never get all the water out, the next day I begged my friends for their fuel pumps, and with those in hand, I laboriously pumped out the rest of the fuel (which took a few hours) as I raised and lowered the front and back to angles it has never seen before. (The last cup of water was gotten with the rear wheels on the ground and the front jacked up with a big floor jack with wood blocks on the jack).
12v-gaspump.jpg


Now it was time to FILL 'er up (and get my windshield washed for free in the rain, just like my Dad said they did in the olden days when you got your tank filled for you at the gas station).
This fuel pump I borrowed from my friend works great.
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I added the first jug of 5.0(something) gallons of gasoline and checked the gauge reading where I was surprised that it wasn't 18.5 divided by 4. Instead, it read essentially what 20 gallons divided by 4 would read.
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Hmm... that's surprising.
Moving on, I drove about 1-1/2 miles (for reasons related to the repair) and then I parked it and added the second jug of 5.0(something) gallons.

The gauge reported the same oddity of almost perfectly half full (with 10 gallons in it now).
tengallons.jpg


At 15 gallons, it still read oddly in almost-perfect five-gallon increments.
fifteengallons.jpg


At "around 14" gallons, the gauge was already past the FULL mark, but I decided to slowly pump the rest of the last five-gallon jug in, and it took it all without spilling; so this is the gauge reading at 20 gallons from bone dry.
twentygallons.jpg


What's my conclusion? Only two things, really:
1. The nominally 18-1/2 gallon tank holds (at least) 20 gallons
2. My sending unit is calibrated for about 5-gallon increments
3. For all but the topmost quarter tank (which is about a 4-gallon increment)

So, my gauge seems to be reading (from full to empty) at 4-5-5-5 gallons respectively (Full, 3/4, 1/2, 1/4).

Actually, if I consider stopping at the empty line, and the fill line itself, it's probably reading closer to 3-5-5-3 gallons (Full line, 3/4 line, 1/2 line, Empty line).

Some caveats are I could fill it until it spills out, but I'm worried about the EVAP system getting drunk on pure fuel.
And, of course I know 5 gallons is close enough to 4.625 gallons because there is slop everywhere.
I also assume you can't use all the fuel in the tank (but I don't know how much fuel is left when you run the tank "empty").

If someone can post how much fuel the 18.5 gallon tank takes after you've run it empty to the point that the engine quit and then you filled it up to full, that would be a useful volume as it tells us how much the fuel pump can't get out.

Since I still had the remaining almost pure water in the fuel lines (and in the fuel filter, which I did not replace yet), I calculated in the original repair thread that there are about 3 ounces of water in the 5/16-inch supply line and 1/4-inch return line (assuming they're both about 30 inches long). Half of that would be in the supply line, where I calculated it would take about 3 minutes of idling to evacuate the 1-1/2 ounces of water in that supply line (but of course it took much longer of cranking to inject the 1-1/2 ounces of water into the engine until the fuel was clean enough to allow the engine to start).

I'm still not sure how to properly dispose of my 13-1/2 gallons of cleaning fluid. (Can the gas be re-used? I suspect not.)
cleaningfluid.jpg
 
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The gas light comes on at 2.5 to 2.0 gallons left in the tank. If the capacity is 18.5 ( per internet) +lets say 2 gallons. The Tank from bare bones empty is really close to 20 gallons. There is where you missing 2 to 2.5 gallons are. They are not counting it. Because they don't want anyone running a tank to nothing. Its extremely hard on the fuel pump to run it completely empty because it uses the fuel to keep the motor cool. So the true capacity is 20-gallons max.

As technically, the tank is empty at 2.5 gallons as its the safety line for the fuel pump to stay cool. Actually, most people will say 1/4 is the low point a few gallons more for just keeping the motor cooler. As the pump is in your fuel tank. There inst much gas left in the tank at 2.5 gallons left either...
 
WOW! Now there's a day's work!
I went for over a year with a pinched evap vent hose (Tank to Canister); the effect of which was that filling the tank was a chore consisting of slowly metering the filler hose and having it pop off frequently. I discovered the pinched hose and replaced it.
Good work, dude!
 
I'd almost agree with Brillo_76, except apparently the 99-00 where expected to use that last 2 gallons since these vehicles got a known faulty fuel level gauge and inclinometer chip in the dash board for more accurate fuel level readings (ironically) from the toyota factory in Japan. I fought tooth and nail to get this to be a recall since I believed this is a safety issue for many reasons (no power brake, steering, heat in remote locations cooling in a desert, ect.), instead it was a TSB and the owner got to pay for the entire thing which cost me $900 10 years ago. I actually just dropped my tank to replace it and the tube assembly again as it rotted out after 10 years, this time I doing the work myself and painting everything since it came with black primer only from Toyota. rant off..
 
Mine is probably closer to 16 gal max with all the dings and dents in it :laugh:

Hell, my gauge hasn't worked in 10 years.
 
My light comes on when I have 80 miles/ or 3-4 gallons left, the light turns off and on for about half that, once its solid on I know I'm getting close.

I read that overfilling the tank/topping off will allow liquid fuel to run into the charcoal canister and ruin the EVAP. I believe there was a TSB for it.

It is interesting though
 
Interesting. When I first got my T4R there was a thread here recommending to assume no more that 16.5 'usable' capacity. Not sure what that really means but I have been going by that to ensure a couple extra gallons are available - maybe I actually have a bit more reserve than I thought....
 
I don't think I have ever filled up with more than maybe 15.5 gallons. Never let it sputter to empty, but the needle has been below the bottom line!

The auto shut-off on fuel pumps (commercial pumps) will shut off the pump well before the tank is full and the level sender is calibrated reasonably close to this level.

You likely overfilled the tank by a lot.... which is ok if you have the '96-'00 evap canister up in the engine bay, but really bad if you have the 01/02 canister down by the tank.

You can modify the vent tube so that the tank will automatically fill up with more fuel... at least to a certain extent.

-Charlie
 
I got a 97 and with 10.5-13 MPG in 100% city. I fill up the tank to the gas cap every time... I rock the runner side to side to get that last drop in! cannot stop in the fuel pump each week...
 
I'd almost agree with Brillo_76, except apparently the 99-00 where expected to use that last 2 gallons since these vehicles got a known faulty fuel level gauge and inclinometer chip in the dash board for more accurate fuel level readings (ironically) from the toyota factory in Japan. I fought tooth and nail to get this to be a recall since I believed this is a safety issue for many reasons (no power brake, steering, heat in remote locations cooling in a desert, ect.), instead it was a TSB and the owner got to pay for the entire thing which cost me $900 10 years ago. I actually just dropped my tank to replace it and the tube assembly again as it rotted out after 10 years, this time I doing the work myself and painting everything since it came with black primer only from Toyota. rant off..

Yes the 99-00 had a TSB...:-( Along with fuel gauge headaches. They really should have fixed that issue. I suspect they got away with it as it was a 100% imported vehicle. Just like the lower ball joint issues. The campaign hit only the late models. However, all the years had the same problem.

When you put your tank together, try lightly scuff it then epoxy primer it really good ... Then Raptor line the darn thing ( after is it completely together.) The really good epoxy primer will thoroughly seal off the steel from rusting then the raptor bonds and gives you a thinker half plastic coating on it to protect against scraps and chips.

I believe that is why they sending units changed in the last 2 years. They no longer rotted away. Emission standards increased and they moved the charcoal canister back by the tank as well. Making a heck of a mess of lines and complexity along with the possibly of filling your evap canister with gasoline. Or the other issue the 01 and 02 have of not being able to fill your tank because of the evap issues. :-(

Seems to be always something.
 
My light comes on when I have 80 miles/ or 3-4 gallons left, the light turns off and on for about half that, once its solid on I know I'm getting close.

I read that overfilling the tank/topping off will allow liquid fuel to run into the charcoal canister and ruin the EVAP. I believe there was a TSB for it.

It is interesting though

Only in the late models 2001 and 2002 can you overfill into the charcoal canister. If your evaporator box is in your front driver side fender 1996-2000 you are good to go all the way up to the gas cap if you really want to. Granted I never do.. I do a few clicks on the pump when filling and call it good.
 
Only in the late models 2001 and 2002 can you overfill into the charcoal canister. If your evaporator box is in your front driver side fender 1996-2000 you are good to go all the way up to the gas cap if you really want to. Granted I never do.. I do a few clicks on the pump when filling and call it good.

This is good to know that you can't overfill the 97 and cause EVAP issues.

Had I known that, I might have gone the last gallon, but I could tell by the gurgling sound that the tank was getting close to full by the 20-gallon point.

It would make sense to me if Toyota designed the tank to hold 20 gallons, but for Toyota to ALSO design it such that the last gallon (or so) would be BELOW the fuel pump inlet so that if WATER ever did get into the tank, you'd need that much water to cause a major problem.

But I had over five gallons of water, so if there was that design feature, I overwhelmed it.

But is there a consensus of how much fuel is left in the tank if you sit it on flat concrete and idle until the engine runs out of fuel? Is it about a gallon?
 
This is good to know that you can't overfill the 97 and cause EVAP issues.

But is there a consensus of how much fuel is left in the tank if you sit it on flat concrete and idle until the engine runs out of fuel? Is it about a gallon?

Well.. I only had to drain 2 tanks so far. I ran them down to E.. I believe it was 5 gallons left. ( was several years ago, So I could be off on the gallons )So the next time I have to drain one. I want to take it down to the idiot fuel light is on then disconnect the return line and run it dry to see exactly how much before the engine dies. Its suppose to be 2.5 to 3 gallons. As I change the fuel pump anyhow so it doesn't matter. Granted, I have a transmission jack now. So I can remove gasoline tanks completely full if I have too. Its just easier to deal with tanks when they are completely empty.

When completely empty there isn't much fuel at all. Look at how that tank is made. They put a well in the tank at the lowest part. It won't even be a gallon. Just a few cups maybe a quart or so. That fuel pump sock is against the bottom of the tank and its not very high. Less then 1/2 inch if that.
 
IIRC, mine died of fuel starvation at around 18.0 gallons, back before I fixed my fuel gauge, and it was lying to me, saying I still had 1/4 tank left. I had also literally coasted to a fuel pump twice, previously.

There are a few possible causes of the fuel gauge not working correctly, but the ground wire addition under the rear seat is what fixed mine. It also happens to be quite cheap, easy and quick to fix. That is the one to try first.

I went about 12 years with my gauge lying through its teeth to me. Now it tells me the truth.
 
IIRC, mine died of fuel starvation at around 18.0 gallons, back before I fixed my fuel gauge, and it was lying to me, saying I still had 1/4 tank left. I had also literally coasted to a fuel pump twice, previously.

There are a few possible causes of the fuel gauge not working correctly, but the ground wire addition under the rear seat is what fixed mine. It also happens to be quite cheap, easy and quick to fix. That is the one to try first.

I went about 12 years with my gauge lying through its teeth to me. Now it tells me the truth.

ah the 99-2000 fuel gauge technical bulletin issue. Yes they like to lie and leave us for dead. The buggers... I still wonder why they loose their tank ground..

However, as old as these are now, its hard to say if a PO didn't put the wrong tank parts in or something too.. As that is always a possibility. Or they get that great deal on amazon and eBay with counterfeit parts could be in play as well.
 
FWIW (not much, I know) - my fuel light came on on the freeway today and I pulled off in about 5 miles for gas. I had to force it to take a full 13 gallons.
 

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