Corolla to Prius gas tank swap

Good news, I’ll be swapping the tank next week. Hopefully no evap codes or problems.

 

So I’m trying to figure something out with the Prius evap system. If the fuel tank pressure sensor detects pressure in the tank it throws a code for a leak in the bladder?

 

So if no pressure in the tank is read but pressure builds will that set a code?

 

OK, reason I ask is because the tank and sending unit I have the swap has no place for a pressure sensor. The pressure sensor will be plugged into the stock Prius harness but will just be laying there . So pretty much it’s just going to be reading ambient air pressure

 

I want to see if I can get away with the evap pressure sensor reading Ambient air pressure at all times And not throwing a code.That’s the only problem I see running into on the swap.

 

Thank you soo much for the videos north Tex. The second one answered my question about the vapor pressure sensor. The Prius has 2 of them. I don’t see the car throwing any codes now. About to get the car on jack stands and start dropping the tank. Wish me luck!

 

Getting ready to swap the tank tonight. Don’t know if I’ll get it all done tonight but it will be done by tomorrow. I’ll try and take lots of pictures of the swap.

 

Let the fun begin!

 

Getting ready to unbolt the straps and drop the tank now. Should be out in the next 20 minutes

 

So unfortunately I ran into a few problems last night.
1. The exhaust is in the way of the tank. I’ll have to get a muffler and pipe from the resonator back off of a corolla.

2. The Corolla tank straps won’t work. I’ll be better off using the stock Prius straps and cutting them to length. They are much more flexible and easier to work with.

3. The check valve on top of the sending unit hits the floor and won’t allow the tank to be flush with the mounting points. It’s only half an inch too tall and right on the edge of the access hole. A slight notch will have to be cut out.

4. The Corolla filler tube neck will have to be cut and extended with some fuel line and clamps. It’s about 2 inches too short from reaching the fuel door location on the Prius.

5. There is a bolt that sticks out from the floor that is a mounting point for the brake line. It hits the top of the tank. It’s factory welded to the floor and had to be cut off and the brake line bent slightly to be flush with the floor. This was an easy fix.

So nothing crazy that shuts this swap down completely but a few hiccups. I had a feeling there would be some. The car is going to have to be put back together today and I’ll source the exhaust at my local yard and this will have to be attempted again but not till October after I move and have more time.

 

The sending unit is off a few inches from the access hole and a notch will have to be cut on the edge so the check valve doesn’t hit the floor. Here you can see the exhaust won’t clear the tank once bolted back up. Figured everyone would want to see what the Corolla tank looked like. Fits the shape of the Prius floor perfect. Will have to redo this in the future and figure out the exhaust, tank straps and filler neck.