Toyota Hilux Long Range Fuel Tank: Complete Buyer’s Guide

A Toyota Hilux long range fuel tank is one of those upgrades that may sound unnecessary until we find ourselves hundreds of kilometres from the nearest reliable fuel station. Suddenly, carrying extra diesel or petrol is not merely convenient—it can completely change how confidently we travel.

The standard Toyota Hilux already has an impressive reputation for long-distance touring, remote-area work, towing, and off-road driving. Yet fuel capacity can become the weak link when we push beyond populated areas. Add a caravan, roof rack, larger tyres, sand driving, headwinds, or low-range four-wheel driving and our real-world fuel consumption can climb surprisingly quickly.

That is where a long-range tank earns its keep.

Depending on the Hilux generation and configuration, aftermarket replacement tanks can substantially increase total capacity. Current examples include a 140-litre ARB Frontier replacement tank, Brown Davis replacement tanks around 150 litres, and certain Long Ranger configurations ranging roughly from the 120-litre region to more than 150 litres. Exact compatibility varies significantly by chassis, engine and equipment, so tank selection should always start with the vehicle rather than the advertised capacity.

Let’s look at what these tanks really offer, how far they can take us, what they cost us in weight, and whether fitting one actually makes sense.

What Is a Toyota Hilux Long Range Fuel Tank?

A Toyota Hilux long range fuel tank is an enlarged fuel storage system designed to increase the distance the vehicle can travel between refuelling stops.

Rather than carrying several jerry cans around the tray, we can store additional fuel underneath the vehicle in a purpose-built tank.

There are generally two approaches:

• A larger replacement tank that takes the place of the factory unit.
• An auxiliary tank that works alongside the original tank.

Replacement tanks are particularly popular because they maintain a tidy installation and avoid occupying valuable cargo space.

For example, Brown Davis offers replacement tanks that retain the standard filler point and original fuel-supply arrangement, while ARB's Frontier system uses a vehicle-specific replacement design intended to maximise available underbody space.

Why Fit a Long Range Fuel Tank to a Hilux?

For city driving? We probably don't need one.

For touring across remote Australia, working on isolated properties, crossing deserts or towing through areas where service stations are few and far between? The story changes dramatically.

Greater Driving Range

The obvious advantage is simple: we can travel farther.

Imagine our Hilux averages 10 L/100 km.

An 80-litre fuel supply theoretically provides:

80 ÷ 10 × 100 = 800 km

A 150-litre tank theoretically provides:

150 ÷ 10 × 100 = 1,500 km

Obviously, we should never plan a journey around draining every last drop. Terrain, wind, towing, tyre pressures and driving style can all change consumption.

Still, the difference is huge.

Fewer Fuel Stops

Stopping every few hundred kilometres is hardly a problem along a motorway filled with service stations.

Remote touring is different.

Sometimes the next fuel stop is not merely inconvenient. It may be closed, temporarily out of fuel or hundreds of kilometres away.

Extra capacity gives us options.

Better Remote-Area Confidence

Fuel anxiety can cast a shadow over an otherwise brilliant trip.

Instead of constantly watching the gauge like a ticking clock, a long-range tank gives us a larger safety buffer.

That doesn't replace proper trip planning, of course. But it certainly makes planning easier.

How Much Fuel Does a Toyota Hilux Long Range Tank Hold?

There is no single capacity because Toyota Hilux long range tanks are designed around specific vehicles.

Current aftermarket examples demonstrate just how varied the market can be.

ARB's current Frontier listing specifies a 140-litre polyethylene tank for compatible Hilux GUN126R diesel models. Brown Davis lists a 150-litre replacement solution for compatible Hilux applications, while Long Ranger products include several capacities depending on fuel type and exact model.

In other words, bigger isn't automatically better.

Fitment matters more.

Replacement Tank vs Auxiliary Tank

Both configurations increase fuel capacity, but they do so differently.

Replacement Long Range Fuel Tank

A replacement tank removes the standard tank and installs a larger unit in its place.

This is often the cleanest solution.

Advantages include:

• No cargo-space sacrifice
• Usually one main filling point
• Relatively simple everyday operation
• Factory-style appearance
• Good use of unused underbody space

For most touring Hilux owners, this is the option we would investigate first.

Auxiliary Fuel Tank

An auxiliary tank supplements the factory tank rather than replacing it.

Fuel may transfer manually or automatically depending on the system.

The potential advantage is greater total fuel storage.

The disadvantages can include extra plumbing, pumps, switches and complexity.

Which Is Better?

For ordinary touring, a replacement tank is generally simpler.

For extremely remote expeditions where maximum range matters, an auxiliary or multi-tank configuration may make sense.

The best system depends on how we actually use our Hilux.

How Far Can a Hilux Travel With a Long Range Tank?

This is the question everyone wants answered.

The basic calculation is:

Driving range = tank capacity ÷ fuel consumption × 100

Suppose our Hilux has a 150-litre tank.

At 8 L/100 km

150 ÷ 8 × 100 = 1,875 km theoretical range

At 10 L/100 km

150 ÷ 10 × 100 = 1,500 km

At 12 L/100 km

150 ÷ 12 × 100 = 1,250 km

At 15 L/100 km

150 ÷ 15 × 100 = 1,000 km

Brown Davis illustrates this principle with its 150-litre Hilux tank, calculating considerably more theoretical range than an 80-litre standard setup when using quoted vehicle-consumption figures.

But theoretical range and sensible touring range are not the same thing.

Never Plan Around the Last Litre

Think of our fuel reserve like emergency savings.

Technically, we could spend everything.

That does not mean we should.

When travelling remotely, we should leave a substantial margin for:

• Detours
• Road closures
• Strong headwinds
• Soft sand
• Mud
• Low-range driving
• Incorrect maps
• Closed fuel stations
• Increased towing consumption

A 1,400 km theoretical range might therefore become a planned range of perhaps 1,100–1,200 km depending on conditions and our chosen reserve.

The more remote the route, the larger our margin should be.

Long Range Tanks and Diesel Hilux Models

Diesel Hilux models are particularly popular with long-distance tourers because diesel engines can deliver useful range alongside strong low-rpm torque.

Long-range tank manufacturers consequently offer numerous diesel-compatible solutions.

ARB's 140-litre Frontier product, for example, is specifically listed as a diesel tank and is constructed from polyethylene. Long Ranger also lists diesel Hilux configurations with capacities extending beyond 140 litres on some applications.

Still, we cannot assume every diesel Hilux accepts the same tank.

Check the Exact Chassis

Before buying, we should confirm:

• Model year
• Chassis code
• 2WD or 4WD
• Single, extra or dual cab
• Diesel or petrol
• Automatic or manual where relevant
• Factory emissions equipment
• Suspension configuration
• Existing aftermarket accessories

That ten-minute check can prevent a very expensive mistake.

Toyota Hilux Petrol Long Range Fuel Tank Options

Petrol Hilux models can also be supported, although the selection may differ from diesel versions.

Long Ranger, for instance, lists petrol replacement systems including capacities around 129 litres and other application-specific higher-capacity versions.

Never fit a tank simply because its physical dimensions look similar.

Fuel-system hardware, venting and certification requirements matter.

Steel vs Polymer Long Range Fuel Tanks

One of the biggest choices is material.

Steel Fuel Tanks

Heavy-duty steel tanks have been used in touring vehicles for decades.

Their strengths include:

• Excellent impact resistance
• Proven construction methods
• Strong mounting points
• Good suitability for rough conditions
• Extensive aftermarket availability

Long Ranger describes some of its tanks as being manufactured from 2 mm aluminised steel, incorporating features such as baffling and expansion chambers.

The downside?

Weight.

Steel also requires appropriate corrosion protection.

Polymer Fuel Tanks

Modern polymer tanks offer a different approach.

ARB's Frontier Hilux tank uses polyethylene and is listed at approximately 25.6 kg for the 140-litre unit. ARB highlights corrosion resistance and the ability to mould the tank into vehicle-specific shapes.

Potential benefits include:

• No rust
• Relatively low tank weight
• Flexible construction
• Complex shapes that maximise capacity

Which Material Would We Choose?

There is no universal winner.

A high-quality steel tank from a respected manufacturer can be excellent.

A well-engineered polymer tank can be equally compelling.

Design quality, mounting integrity and correct installation matter more than simply declaring one material superior.

How Much Weight Does Extra Fuel Add?

Here comes the part people often forget.

Fuel is heavy.

Diesel weighs roughly 0.83–0.85 kg per litre, while petrol is lighter at roughly 0.74 kg per litre, although density varies with fuel formulation and temperature.

Suppose we add 70 litres of diesel compared with the standard setup.

That could mean roughly:

70 × 0.84 = 58.8 kg

And that is just the extra fuel.

Then we add the tank itself.

Suddenly our long-range upgrade may account for 80 kg or more of additional loaded vehicle mass.

Payload Matters More Than Most Owners Realise

A Hilux may feel unstoppable, but its legal payload has limits.

Everything counts toward vehicle mass:

• Passengers
• Bull bar
• Winch
• Canopy
• Drawers
• Roof rack
• Fridge
• Water
• Recovery gear
• Camping equipment
• Tow-ball download
• Long-range fuel

Fuel capacity should therefore be considered within the whole vehicle build.

Don't Build Accessories in Isolation

This is where many touring builds go wrong.

We install:

a bull bar,

then a winch,

then drawers,

then a canopy,

then a second battery,

then 150 litres of fuel.

Each modification seems reasonable on its own.

Together, they can eat payload like termites through timber.

A weighbridge check after major modifications is one of the smartest things we can do.

Does a Long Range Fuel Tank Reduce Ground Clearance?

It can—but a properly designed system should minimise the problem.

Some aftermarket tanks are deliberately shaped to maintain useful clearance and departure or ramp-over geometry.

Brown Davis, for example, highlights a tapered tank profile intended to reduce exposure to frontal impacts and improve ramp-over clearance. Long Ranger similarly markets high-clearance options for certain Hilux configurations.

Still, we should physically inspect installation drawings.

Pay Attention to the Lowest Point

The advertised capacity tells only half the story.

Ask:

• Does the tank sit below the chassis rails?
• How close is it to the rear axle?
• Does it affect spare-wheel placement?
• Is a bash plate supplied or required?
• Will suspension compression cause interference?

If we regularly crawl across rocky terrain, these questions become especially important.

Will the Factory Fuel Gauge Still Work?

Usually, manufacturers try to retain the factory sender and fuel gauge, but behaviour can change.

With a physically larger tank, the gauge may remain near "full" for longer than we are used to.

Distance-to-empty calculations can also behave differently.

ARB even notes that fuel-gauge or distance-to-empty behaviour may vary from factory operation with some tank installations.

So after fitting a new tank, we should learn its behaviour rather than blindly trusting the dashboard on our first remote journey.

Calibrate Our Expectations

For the first few fills:

1. Fill the tank completely.
2. Reset the trip computer.
3. Record kilometres travelled.
4. Record litres added at the next fill.
5. Calculate actual consumption.
6. Observe gauge behaviour.

After several cycles, we will know the vehicle far better than any brochure does.

How Installation Typically Works

Professional installation is strongly recommended.

A replacement-tank installation generally involves:

1. Safely draining or reducing fuel in the original tank.
2. Disconnecting fuel lines and electrical connections.
3. Removing the factory tank.
4. Transferring compatible factory components where required.
5. Installing the larger tank and brackets.
6. Connecting filler, breather and fuel lines.
7. Reconnecting the sender or pump.
8. Adding fuel.
9. Testing carefully for leaks.

Brown Davis lists a two-hour fitting time for some compatible Hilux replacement tanks, while actual installation time will depend on tank design and vehicle configuration.

Why Leak Testing Is Essential

Fuel systems are not an area for shortcuts.

After installation, fittings, hoses, breathers and mounting points should be inspected carefully.

ARB specifically notes that correct fitting of some long-range tanks requires filling the tank to carry out leak testing.

That is not bureaucracy.

It is basic safety.

Long Range Tank Problems to Watch For

Good systems are generally reliable, but installations can still develop problems.

Slow Filling or Pump Clicking Off

Possible causes include:

• Breather restriction
• Incorrect hose routing
• Kinked filler hose
• Ventilation issue

Fuel Gauge Behaving Strangely

A changed tank shape can alter how the sender translates fuel level into gauge movement.

The gauge may not fall linearly.

Fuel Smell

A persistent fuel smell should never be ignored.

Possible causes include:

• Loose fittings
• Damaged seals
• Venting problems
• Leaks around hoses

Rattling or Movement

The tank should be securely mounted.

Any movement deserves immediate inspection.

Fuel Slosh

Internal baffling helps control fuel movement during cornering and off-road driving. Brown Davis and Long Ranger both describe baffling or anti-surge features in their tank designs.

Long Range Fuel Tank vs Jerry Cans

Why not simply carry jerry cans?

For occasional trips, that can make perfect sense.

Jerry cans are:

• Relatively inexpensive
• Removable
• Easy to replace
• Useful for emergencies

But they also need safe storage.

Fuel containers should never simply roll around in an enclosed cargo area.

A proper long-range tank keeps the fuel low in the vehicle and frees up cargo space.

Long Range Tank Advantages

A built-in tank offers:

• More convenient refuelling
• Better cargo utilisation
• Lower fuel storage position
• No manual pouring
• Cleaner touring setup

For frequent travellers, that convenience becomes difficult to give up.

Long Range Tank and Towing

Towing makes extra fuel capacity particularly useful.

A Hilux that normally averages 8–9 L/100 km might consume substantially more while towing a heavy caravan, depending on terrain, speed and aerodynamic drag.

And aerodynamic drag is sneaky.

A large caravan can behave like towing a small house into a headwind.

Calculate Range Using Towing Consumption

Never calculate touring range using your unloaded highway figure.

If the Hilux consumes 14 L/100 km while towing and carries 150 litres:

150 ÷ 14 × 100 = 1,071 km theoretical

With a sensible reserve, practical planning range will be lower.

That is the number we should use.

Can a Long Range Tank Save Money?

Potentially.

A larger tank can allow us to fill where fuel is cheaper rather than being forced to buy at an expensive remote station.

Suppose fuel costs:

• $1.90/L in a regional town
• $2.50/L at a remote stop

Buying an additional 60 litres before leaving town could represent a substantial difference.

But we should not fit a long-range tank purely to chase cheap fuel.

The Upgrade Takes Time to Pay Back

The tank, installation and additional hardware may cost far more than the savings from individual fills.

Its real value comes from:

• Convenience
• Range
• Safety margin
• Remote touring flexibility

Fuel-price savings are a bonus.

Who Should Buy a Toyota Hilux Long Range Fuel Tank?

We would strongly consider one if we regularly:

• Travel through remote areas
• Tow long distances
• Explore outback tracks
• Work on isolated farms or mine sites
• Camp far from major towns
• Drive routes with unreliable fuel availability
• Undertake overlanding expeditions

Who Probably Doesn't Need One?

We might skip it if the Hilux spends almost all its time:

• Commuting in cities
• Driving short suburban trips
• Operating near fuel stations
• Carrying heavy loads close to maximum payload

Why haul additional tank weight everywhere if we rarely need the extra capacity?

The best modification is not always the biggest one.

It is the one we actually use.

How to Choose the Best Toyota Hilux Long Range Fuel Tank

Before buying, check these factors carefully.

1. Vehicle Compatibility

Confirm the exact year, chassis and engine.

2. Capacity

Choose realistic capacity rather than simply maximum capacity.

3. Material

Consider steel versus polymer based on weight, terrain and manufacturer design.

4. Ground Clearance

Check how far the tank hangs below surrounding components.

5. Payload

Calculate fuel weight together with all accessories and passengers.

6. Filler Arrangement

A good system should be straightforward to fill and properly vented.

7. Gauge Compatibility

Understand whether the factory gauge and distance-to-empty display behave normally.

8. Warranty

Choose a manufacturer with clear product support.

9. Installer Experience

An excellent tank installed badly is still a bad setup.

Best Capacity for Touring

For many Hilux tourers, something in the general 120–150 litre region represents a useful balance between range and packaging, although available capacities vary by vehicle.

Current examples reinforce that range: ARB lists a 140-litre Frontier tank, Brown Davis offers a 150-litre replacement example, and Long Ranger's Hilux catalogue includes multiple capacity options.

A 150-litre tank sounds impressive, but we should still ask:

Do we actually need 150 litres?

If 120 litres already gives comfortable range between our planned fuel stops, carrying another 30 litres only adds weight.

How to Calculate the Capacity We Need

Use this simple formula:

Required litres = planned distance × consumption ÷ 100

Suppose the longest distance between reliable fuel stops is 750 km and our loaded Hilux uses 12 L/100 km.

750 × 12 ÷ 100 = 90 litres

Now add a reserve.

A 20% buffer gives:

90 × 1.20 = 108 litres

A tank around 120 litres would therefore provide reasonable breathing room.

That's a much smarter approach than buying the biggest tank simply because it exists.

Long-Distance Touring Tips After Installation

Once the tank is fitted, we should:

• Track real fuel consumption.
• Avoid routinely running the tank nearly empty.
• Inspect brackets during servicing.
• Check hoses after difficult off-road trips.
• Keep fuel-system components clean.
• Know the actual usable capacity.
• Plan fuel stops before entering remote areas.
• Carry emergency fuel only where genuinely necessary.

Don't Forget Fuel Quality

More capacity means fuel may remain in the vehicle longer.

If the Hilux sits unused for extended periods, especially in harsh environments, fuel quality deserves attention.

Water contamination and dirty fuel can cause far more expensive problems than running out.

Is a Toyota Hilux Long Range Fuel Tank Worth It?

For the right owner, absolutely.

It turns the Hilux from a vehicle that can travel far into one that can travel far without constantly arranging the journey around service stations.

That distinction matters.

A long-range tank is not glamorous. It doesn't make the engine louder, the suspension taller or the wheels shinier.

Yet somewhere deep in the outback, with the next fuel stop several hundred kilometres away, it may become one of our favourite modifications.

The important thing is choosing intelligently.

Capacity, payload, ground clearance, tank construction and vehicle compatibility all need to work together.

Get those right and the Toyota Hilux long range fuel tank becomes less like an accessory and more like freedom bolted beneath the chassis.

Conclusion

A Toyota Hilux long range fuel tank is one of the most practical modifications available for owners who genuinely travel long distances.

Depending on the Hilux and aftermarket system, replacement capacities around 126, 140, 149, 150 or even 152 litres can be available, demonstrating why we should never assume one specification applies to every Hilux.

More fuel means more range, fewer stops and greater flexibility, but it also means extra weight.

The smartest setup is therefore not necessarily the largest tank.

We want enough fuel to comfortably cover our longest realistic route, plus an appropriate reserve, without unnecessarily compromising payload or off-road clearance.

Choose a reputable vehicle-specific system, have it installed correctly, learn how the gauge behaves and calculate range using real-world consumption.

Do that, and our Hilux can keep rolling long after ordinary fuel tanks start asking where the next bowser is.

FAQs About Toyota Hilux Long Range Fuel Tanks

1. How many litres does a Toyota Hilux long range fuel tank hold?

Capacity depends on the Hilux model and manufacturer. Current aftermarket examples include roughly 126-litre, 140-litre, 149-litre, 150-litre and 152-litre configurations. Exact fitment should always be verified for the specific model.

2. How far can a Hilux travel with a 150-litre fuel tank?

At 10 L/100 km, the mathematical maximum is about 1,500 km. At 12 L/100 km, it is around 1,250 km. Actual range will be lower once we account for reserve fuel, towing, terrain and driving conditions.

3. Does a long range fuel tank affect Hilux payload?

Yes. Both the larger tank and additional fuel add weight to the vehicle. Diesel alone weighs roughly 0.84 kg per litre, so extra capacity can consume a meaningful portion of available payload.

4. Will the original Hilux fuel gauge work with a long range tank?

Many systems retain factory fuel-level components, but the gauge or distance-to-empty calculation may behave differently because the tank's shape and capacity have changed. Some manufacturers specifically warn that gauge behaviour may differ from factory operation.

5. Is a steel or polymer Hilux long range fuel tank better?

Neither is automatically superior. Steel offers proven strength and durability, while modern polyethylene tanks can be lighter, corrosion-resistant and shaped efficiently around the chassis. Manufacturer quality, fitment, mounting design and intended use matter more than material alone.

If you want to know other articles similar to Toyota Hilux Long Range Fuel Tank: Complete Buyer’s Guide you can visit the category Driving.