Toyota Hilux Long Range Fuel Tank: Capacity, Range, Cost and Best Options

A Toyota Hilux long range fuel tank is one of the most practical upgrades we can make if we regularly travel long distances, tow a caravan, explore remote areas or simply want to spend less time stopping at fuel stations.

The standard Toyota HiLux fuel tank is adequate for normal commuting and highway driving, but Australia is a huge country. Once we start touring through regional areas, heading off-road or towing something heavy, the distance between fuel stops can quickly become an important part of trip planning.

That is where an aftermarket long range tank makes sense.

Depending on the HiLux model and the tank manufacturer, replacement tanks around 126 to 153 litres are available, compared with approximately 80 litres on many factory HiLux configurations. Some popular current solutions for 2015-on diesel HiLux models include ARB's 140-litre Frontier tank and Brown Davis replacement tanks around 145–150 litres.

But capacity is only part of the story. We also need to consider vehicle weight, fuel economy, ground clearance, fuel gauge accuracy, accessories and whether the tank actually fits our particular HiLux.

Let's look at everything we should know before installing one.

What Is a Toyota Hilux Long Range Fuel Tank?

A long range fuel tank is an enlarged fuel tank designed to increase the amount of fuel our Toyota HiLux can carry.

In many cases, it completely replaces the original Toyota tank.

Instead of carrying around 80 litres, we might have 126, 140, 145, 149 or even 150+ litres available depending on the model and configuration.

That gives us considerably more driving range without needing to carry several jerry cans in the tub.

There are also auxiliary fuel tanks. Rather than replacing the factory tank, these work alongside it and transfer fuel into the main tank or supply fuel through another system.

For most modern HiLux owners, however, a vehicle-specific replacement tank is usually the simplest setup.

How Big Is the Standard Toyota Hilux Fuel Tank?

Fuel tank capacity varies between HiLux generations and specifications, so we should always confirm our exact model before purchasing an aftermarket tank.

Many current and recent Australian-market HiLux models use a tank of approximately 80 litres.

For comparison, Brown Davis states that its 2015-on replacement tank substitutes the factory 80-litre unit with a 150-litre tank. Its newer N90 HiLux replacement tank also lists 150 litres of capacity against an 80-litre standard tank.

Older HiLux generations may differ.

For example, Brown Davis lists a 153-litre replacement tank for 2005–2015 4WD models and compares it with a 76-litre standard tank for that application.

This is why model year alone isn't enough. Engine, drivetrain, body style and accessories can affect compatibility.

Toyota Hilux Long Range Fuel Tank Capacities

There isn't one universal capacity for every HiLux.

The aftermarket offers several options.

Exact compatibility varies considerably by year, engine and drivetrain. ARB's current Australian material, for example, lists its Hilux Frontier replacement tank at 140 litres, while Brown Davis offers 145-litre polymer and 150-litre steel solutions for relevant GUN126R applications.

So rather than automatically choosing the largest number, we should select the tank that best suits our actual vehicle and intended use.

140L Toyota Hilux Long Range Fuel Tank

A 140-litre tank represents a substantial increase over an 80-litre factory tank.

ARB currently offers its Frontier 140L Polymer Long Range Fuel Tank for compatible Toyota HiLux diesel models.

The tank is constructed from cross-linked polyethylene rather than steel. ARB lists a tank weight of approximately 25.6 kg and describes it as a replacement tank designed to maximise unused space beneath the vehicle.

Going from 80 litres to 140 litres gives us 60 litres of extra nominal fuel capacity.

That represents a 75% increase in total capacity.

For touring, that difference is enormous.

150L Toyota Hilux Long Range Fuel Tank

The 150L Toyota Hilux long range fuel tank is another popular configuration.

Brown Davis offers a 150-litre replacement tank for compatible 2015-on 4WD diesel HiLux models. The manufacturer says the tank replaces the factory unit, retains the original filler location and allows the spare wheel to remain in its factory position.

An 80-to-150-litre upgrade adds approximately 70 litres.

That means fuel capacity rises by about 87.5%.

For someone driving across regional Australia, that's much more useful than simply having bragging rights about tank size.

It can turn a route that previously required careful fuel-stop planning into a considerably easier journey.

145L Polymer Long Range Tank

Another interesting option is a 145-litre polymer tank.

Brown Davis offers a 145L poly replacement tank for compatible GUN126R HiLux models.

Like the company's larger steel alternative, it replaces the original tank and retains the standard filler point.

Poly tanks appeal to many touring owners because they don't rust and can offer useful weight advantages depending on design.

Steel, on the other hand, remains extremely popular in Australian touring vehicles because of its proven durability and the huge variety of vehicle-specific designs available.

Neither material is automatically the right answer for everyone.

Construction quality and vehicle compatibility matter more than simply choosing steel or polymer.

How Much Extra Range Does a Long Range Tank Give a Hilux?

This is probably the question most owners care about.

We can estimate theoretical range with a simple calculation:

Fuel capacity ÷ fuel consumption × 100 = theoretical range

Suppose our HiLux averages 9.0 L/100 km.

With an 80L tank:

80 ÷ 9 × 100 = approximately 889 km

With a 140L tank:

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140 ÷ 9 × 100 = approximately 1,556 km

With a 150L tank:

150 ÷ 9 × 100 = approximately 1,667 km

That's an enormous difference.

Of course, these are theoretical numbers.

We should never plan a remote-area journey assuming we'll use every last litre.

Real consumption also changes with vehicle configuration and driving conditions.

Real-World Toyota Hilux Long Range Fuel Tank Range

The advertised range of a large tank can look amazing, but real-world driving is rarely identical to laboratory or official fuel-consumption figures.

A HiLux might use significantly more diesel when we add:

• a bull bar, winch and roof rack
• larger all-terrain or mud-terrain tyres
• suspension modifications
• camping equipment
• passengers and luggage
• a caravan, camper trailer or boat
• sustained high-speed driving
• sand, mud or steep off-road terrain

This is why our real touring range should always include a safety reserve.

If our modified HiLux averages 11 L/100 km instead of 8 L/100 km, a 150-litre tank theoretically provides about 1,364 km rather than 1,875 km.

The tank hasn't changed.

Our actual operating conditions have.

Toyota Hilux Long Range Fuel Tank for Touring

Touring is arguably where this upgrade makes the most sense.

Imagine driving through an area where fuel stations are hundreds of kilometres apart.

With a standard tank, we may need to fill up at almost every opportunity.

With 140–150 litres available, we have more flexibility.

We might also avoid relying on isolated fuel stations being open or having diesel available when we arrive.

That's particularly useful when travelling through remote areas of Western Australia, the Northern Territory, South Australia or inland Queensland.

A bigger tank doesn't eliminate the need for route planning, but it gives us a much larger margin.

Toyota Hilux Long Range Fuel Tank for Towing

Towing can dramatically increase fuel consumption.

A HiLux that normally averages 8–9 L/100 km might consume 12, 14 or even more litres per 100 km while towing, depending on the load, road, weather and speed.

Consider a HiLux towing a caravan while averaging 14 L/100 km.

An 80L tank theoretically provides about:

571 km

A 150L tank theoretically provides:

1,071 km

That extra range can transform long-distance towing.

We won't necessarily drive 1,000 km without stopping—we shouldn't—but we're much less dependent on finding fuel every few hundred kilometres.

Replacement Tank vs Auxiliary Tank

Both systems can increase fuel capacity, but they work differently.

A replacement tank removes the factory tank and installs a larger unit in approximately the same area.

An auxiliary tank adds a second fuel storage system.

For a modern HiLux, a replacement tank is often attractive because everything remains relatively simple. We keep one main tank and usually retain the original fuel filler and supply arrangement.

An auxiliary tank can make more sense when extremely high capacity is required or when a vehicle configuration makes a large replacement tank impractical.

However, extra plumbing, transfer pumps or gravity-feed systems can introduce additional complexity.

Brown Davis, for example, also markets tray-mounted auxiliary solutions, demonstrating that the best approach depends heavily on how the HiLux is configured.

Steel vs Polymer Long Range Fuel Tanks

This debate comes up regularly among 4WD owners.

Steel Fuel Tanks

Steel has been used for aftermarket 4WD tanks for decades.

A well-designed steel tank can be extremely tough and is often engineered with internal baffling, strengthened mounting points and protective geometry for off-road use.

Brown Davis' 150L HiLux tank is an example of the traditional heavy-duty replacement approach.

Polymer Fuel Tanks

Polymer tanks have become increasingly popular.

ARB's Frontier HiLux tank uses cross-linked polyethylene and has an 8 mm wall thickness through much of the structure, increasing around corners. ARB describes the material as impact resistant, UV stable and rust-proof.

Polymer can also flex under impact rather than permanently deforming in the same way some metal structures can.

Ultimately, both materials can work extremely well when the tank is properly designed.

Does a Long Range Fuel Tank Reduce Ground Clearance?

It depends on the tank.

This is one specification we should check carefully before buying.

A badly positioned tank could compromise ramp-over clearance or become more exposed to rocks and other obstacles.

Good vehicle-specific tanks are designed around this problem.

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Brown Davis says its 150L HiLux replacement tank remains at approximately the same height as the standard tank while using a tapered front section to help with clearance.

Nevertheless, we shouldn't assume every aftermarket product behaves the same way.

Owners who regularly tackle technical off-road tracks should pay particularly close attention to the lowest point of the tank.

How Much Does 150 Litres of Diesel Weigh?

This is one of the most overlooked aspects of fitting a bigger tank.

Diesel weighs roughly 0.83–0.85 kg per litre depending on temperature and composition.

Using approximately 0.84 kg/L:

150 litres × 0.84 kg = around 126 kg of diesel

An 80-litre load weighs approximately:

67 kg

So filling a 150L tank instead of an 80L tank can mean carrying roughly another 59 kg of fuel, before considering differences in tank weight.

That matters because every HiLux has limits for GVM, axle loads and payload.

If we've already added a bull bar, winch, canopy, drawers, fridge, roof rack, passengers and towing ball load, another 50–60 kg shouldn't be ignored.

Does a Long Range Tank Affect Hilux Payload?

The tank itself doesn't magically change the legal payload of our vehicle.

Extra fuel becomes part of the load carried by the vehicle.

Therefore, filling a larger tank reduces the amount of payload available for everything else.

This can become especially important with heavily modified touring builds.

Let's say our tank lets us carry an additional 70 litres of diesel.

At roughly 0.84 kg/L, that's approximately 59 kg of extra fuel.

Our usable payload has effectively dropped by around that amount when the tank is full.

For a lightly modified HiLux, that may not be a major issue.

For a fully equipped touring or towing build close to its maximum permitted mass, it matters a lot.

Will the Toyota Hilux Fuel Gauge Still Work?

Usually yes, but not necessarily in exactly the way we expect.

One common characteristic of replacement long range tanks is that the original fuel gauge may no longer move at the same rate.

The sender still measures fuel level, but the shape and capacity of the new tank are different.

Brown Davis specifically notes that the distance-to-empty function may not remain accurate with its 145L HiLux replacement tank.

This doesn't necessarily mean there's a problem with the tank.

It means we need to learn how the factory gauge behaves with the new capacity.

A trip meter and our own measured average fuel economy are extremely useful after installation.

Toyota Hilux Long Range Fuel Tank Installation

Installation difficulty varies by tank and HiLux generation.

A vehicle-specific replacement tank generally requires the original tank to be removed before the new unit is installed using appropriate mounts, fuel lines, venting and factory components.

Brown Davis lists an estimated fitting time of around two hours for some of its current HiLux 150L applications and says no vehicle modifications are required for those specific fitments.

That doesn't mean every HiLux installation takes two hours.

Accessories can change everything.

Aftermarket exhaust systems, underbody protection, trays, drawers and suspension configurations can potentially interfere with a tank.

Professional installation is therefore worth considering, particularly on a vehicle used for remote touring.

Compatibility With the Toyota Hilux 48V Models

This deserves special attention because newer HiLux configurations aren't necessarily identical underneath.

The introduction of Toyota's 48-volt system means owners shouldn't assume a tank designed for an earlier GUN126R automatically fits a newer variant.

Brown Davis, for example, identifies a separate part number for compatible 2024-on 48V 4WD applications of its 150L tank. ARB also specifically references compatibility with selected SR 48V, SR5 48V and Rogue configurations for its current 140L product.

Always confirm the exact model, build date, engine, drivetrain and 48V status when ordering.

Long Range Fuel Tank for the New Toyota Hilux N90

The newest-generation HiLux introduces another compatibility consideration.

Aftermarket manufacturers have already started developing vehicle-specific long range solutions.

Brown Davis lists a 150-litre replacement tank for the N90-generation HiLux, covering relevant late-2025 and 2026-on diesel 4WD applications. The company states that it retains the original filler point and spare-wheel position while replacing the factory tank.

That is useful for buyers moving into the new generation because long-distance touring upgrades aren't limited to older GUN126R vehicles.

However, we should never purchase a previous-generation tank based purely on its capacity.

Generation-specific compatibility is essential.

Toyota Hilux Long Range Fuel Tank Cost Australia

Prices vary considerably according to tank construction, capacity, model and installation.

As one current example, ARB lists its 140L Frontier tank at around A$1,638 before the quoted fitting charge on its Australian website at the time of writing. Prices naturally change, so this should be treated as a reference rather than a permanent figure.

Other systems can cost more or less.

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We also need to account for installation, fuel used for leak testing and any additional components or modifications required.

The cheapest tank isn't necessarily the cheapest long-term solution.

For a remote touring vehicle, proper design, mounting strength, compatibility and manufacturer support are usually worth paying for.

Is a Toyota Hilux Long Range Fuel Tank Worth It?

For some HiLux owners, absolutely.

For others, probably not.

If we mostly commute around Sydney, Melbourne, Brisbane, Perth or Adelaide and pass fuel stations every few kilometres, doubling our fuel capacity doesn't provide much practical benefit.

For touring, towing and remote-area use, the equation changes considerably.

A large tank gives us freedom to choose where we refuel, increases our safety margin between towns and reduces the need to carry several fuel containers externally.

There's also convenience.

Even during normal regional driving, travelling 1,000 km or more between potential refuelling stops can mean fewer interruptions.

Long Range Tank vs Jerry Cans

Jerry cans remain useful because they're inexpensive and portable.

They can also serve as an emergency reserve.

But carrying 60 or 70 additional litres in jerry cans requires several containers.

Those containers take up valuable space and must be safely secured. They also need to be manually handled when transferring the fuel.

A replacement tank puts the extra diesel underneath the vehicle and integrates it into the vehicle's normal fuel system.

For frequent touring, that's generally much more convenient.

Jerry cans can still have a role on extremely remote trips, but many owners find that a properly designed long range tank handles most of their additional fuel requirements.

How to Choose the Best Long Range Fuel Tank for a Toyota Hilux

The largest tank isn't automatically the best one.

We should start with compatibility and then consider how the vehicle is actually used.

The most important factors include tank capacity, construction material, ground clearance, additional tank weight, spare-wheel compatibility, exhaust clearance, tray compatibility, fuel gauge behaviour, warranty, mounting design and availability of professional installation.

For someone doing occasional weekend trips, 126–140 litres might already provide more range than necessary.

A remote touring or caravan-towing build may benefit from approximately 145–150 litres.

The correct answer depends on our actual fuel consumption and travel pattern rather than simply chasing maximum capacity.

Toyota Hilux Long Range Fuel Tank Range Calculator

We can easily estimate how much range an upgrade could give our HiLux.

Use:

Tank capacity ÷ average L/100 km × 100

Here are some examples.

These are theoretical numbers.

Our safe trip-planning distance should always be lower.

Wind, tyres, towing, off-road conditions and vehicle load can increase consumption significantly.

Toyota Hilux Long Range Fuel Tank Pros and Cons

The biggest advantage is obvious: range.

We can travel much farther between fuel stops and carry the extra fuel in a purpose-built location rather than filling the tub with containers.

The disadvantages are equally worth considering.

A long range tank costs money, adds weight and can affect fuel-gauge behaviour. Filling 140–150 litres at once also makes individual fuel bills considerably larger, even though total fuel consumption doesn't increase merely because we've fitted a bigger tank.

Most importantly, we need to account for the extra fuel weight when calculating payload.

For touring owners who understand those compromises, the benefits often outweigh the drawbacks.

Frequently Asked Questions

How big is a Toyota Hilux long range fuel tank?

Aftermarket Toyota HiLux long range tanks commonly range from approximately 126 litres to more than 150 litres depending on the year, engine and design. Popular current options for compatible modern diesel HiLux models include 140L, 145L, 149L and 150L tanks.

How far can a Hilux go with a 150L tank?

It depends on fuel consumption. At 10 L/100 km, a 150L tank has a theoretical range of around 1,500 km. At 12 L/100 km, theoretical range falls to around 1,250 km. We should always maintain a safety reserve rather than planning to use every litre.

Can you put a bigger fuel tank in a Toyota Hilux?

Yes. Several Australian aftermarket manufacturers offer replacement long range tanks designed specifically for different Toyota HiLux generations and variants. Exact compatibility should always be checked using the vehicle's model, build date, engine and drivetrain.

Does a long range fuel tank increase fuel consumption?

Not directly. A larger tank doesn't inherently make the engine use more fuel. However, carrying additional diesel adds weight, which can cause a small increase in consumption. The effect is generally far smaller than changes caused by towing, tyres, aerodynamic accessories or aggressive driving.

Is a 140L or 150L tank better for a Hilux?

It depends on our needs. A 140L tank already provides around 75% more nominal capacity than an 80L tank. A 150L tank offers approximately 87.5% more capacity. The better option is the one that fits our particular HiLux correctly while maintaining suitable clearance, payload and accessory compatibility.

Final Thoughts on the Toyota Hilux Long Range Fuel Tank

A Toyota Hilux long range fuel tank is one of those modifications that can genuinely change how we use our vehicle.

Going from approximately 80 litres to 140 or 150 litres can add hundreds of kilometres of usable touring range.

For remote travel, caravan towing and long-distance Australian road trips, that extra capacity means fewer fuel stops and much more flexibility when planning routes.

Current aftermarket options include approximately 140L polymer tanks from ARB, 145L polymer and 150L replacement solutions from Brown Davis, plus various Long Ranger configurations depending on the vehicle.

The key is not simply choosing the biggest tank available.

We need to consider our HiLux generation, drivetrain, 48V configuration where applicable, accessories, ground clearance, payload and real-world fuel consumption.

Get those details right and a long range fuel tank can turn the HiLux into an even more capable touring vehicle—one that's far less dependent on where the next fuel station happens to be.

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