2007 Prius with 210k miles. Looking at replacing gas tank before fuel pump fails. My 2006 went at 250k. Have tried searching here and Google in general for info without much luck. I figure there's a couple straps to unbolt, some wires to disconnect and the fuel hose. Anyone have any tips on where these are and how to get at them? Or anything I may be overlooking? Thanks in advance for the help! Jim
That is some serious preventative work you plan to do. Not to mention expensive if you're going to use a new unit. Are you going new, or lower miles used? Our old 2005 is still going strong at 299,999+ miles, now owned by sons friend. My sons current 2005 is still going strong at 195k+ miles My old white 2005 had 290k+ when it got totaled. It was going strong, until it followed the bidding of a large SUV and went strongly over some curbs/fence/etc My current 2007 is at ~188k and going strong. Swapping a gen 2 fuel tank as a preventive maintenance item has never even occurred to me. I could see having one in standby just in case it's ever needed (I have a spare 2007 parts car that has come in very handy a couple times), but I think the failure rate of the fuel system is pretty low. But now I'm wondering if I should pull it out ahead of time in case I ever need it. I have several days of vacation coming up next week that still have plenty of 'open time' available. If I yank it out this weekend, I'll put some follow up info here.
This might help, haven't really read through it. If it's linking to other sections you need, just let me know:
Thank you for this pdf, Mendel Leisk. I’ve been chasing the gremlin of a stubborn fueling issue. My ‘04 doesn’t allow any fuel pump to fuel normally at all, even at the handle’s lowest setting. The fuel backs up and clicks off from the very beginning so I have to nurse the gas in by dribbling it. At 6-8 gallons doing this is both time consuming and a little hard on my hands. My problem doesn’t seem to be the back pressure between the housing and the bladder which may prevent the bladder from expanding during fueling. I disconnected the vent tube next to the filler tube on the tank and it made no difference during fueling. (Also didn’t throw any codes driving that way.) I suspect there may actually be something blocking the filler tube itself on the way to the tank connection. That is my next try in any case, to take that off and blow it out or replace it with a junk yard tube from a newer year. This is a rather creative piece of pipe work! I appreciate seeing how all the different tubes are arranged in the manual. Thank you for posting it.
To follow up, new fuel filler neck assembly was gotten from a 2009 and installed on my ‘04. The design of the complicated assembly was not dramatically different but there were some noticeable changes between the years. The result, although my car still does not allow me to fill it as easy as some Gen 2 Prius, there is definitely improvement in the speed it allows me to fill before it clicks off the nozzle. -I’ll take the new fill speed over the previous limitations any day.
