Fuel tank issue---anyone else having it?

I'd have the dealer contact the Toyota national representative.

I believe that the fuel tank is part of the emission control system and has an extended warranty.

Unless you handed directly on an object on the road on the downward stroke of the suspension and imparted an "overpressure" condition in the tank, it is a manufacturing defect.

 

They may also cover this cost on a good will warranty if asked. Can't say I've heard of this before. This car is not salvaged right?

 

This is why I bought the extended warranty. Already, my nav unit has been replaced on the warranty. Replacement cost for the Nav unit is $2200 plus labor. Warranty cost was $2300. You've been given some good suggestions. I've heard that the dealers sometimes will do this kind of premature failure work at the warranty labor rate. This will save you some money. Ask, it can't hurt.

 

Unless you did something to damage the tank, this is on Toyota. The gas tank IS part of the emission control system. It is where emissions begin. You are Bethesda, meaning you have access to the local news media of the nation's capital. I'd be very clear with your dealer that if this isn't covered under warranty, you'd like to exactly why...so that when you explain what happened to Channel 7 you have your facts right.

They will take care of you I'm pretty sure.

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Edit, strike what I said above. It isn't covered. I found this pdf:

http://owners.honda.com/documentum/warranty/partslist/apl32586.pdf

If you were someplace else it would be, but it isn't covered under the mandatory Federal warranty.

I would still seek to have it covered as a good will item. And I'd still consider using the local media if you need to. Leaking gas in Prius...isolated incident or hidden danger on our streets, film at 11...

 

Wouldn't be too hard to replace for about $400, if you do it, yourself.

It'll take 2-3 hours. Make sure that you extinguish the pilot light on the water heater.

Better done outside.

 

This should be covered under emissions system warranty, if nothing else. I'd bring the full court press to avoid paying that bill.

 

No thankfully, this is not yet a widely or commonly reported problem. And sorry but despite your unfortunate reality, I hope it doesn't become one.

One of the big reasons I waited (and waited) and eventually got a Gen 3 Prius over what would of been a good bargain last model year Gen 2 Prius was the replacement of the Fuel Bladder with a "regular" gas tank.

I live in Oregon a state that doesn't allow you to pump your own gas, so the idea of potential fuel fill issues that sometimes do arise with the Gen 2 fuel bladder seemed like a real potential PIA.

BUT...I remember reading about the "new" Fuel tank in the Gen 3 Prius. If I remember correctly Toyota defined the new tank as being made out of a " light weight resin" . I remember having some concern at the time about the durability of a gas tank made out of resin.

So no...I don't think a lot of people have reported this problem. And I hope it doesn't become a growing problem as the Gen 3 Prius age.

 

Plastic fuel tanks are "blow molded" from a combination of HDPE and polyamide or Nylon, either laminated or homogenous, as the material has to meet low permeation rates to comply with EPA Regulations.

Blow molding leaves thin places, especially at corners away form the port or channel where the air is injected. Just examine a milk jug.

If the material cools too quickly, a defect can occur that would eventually crack from expansion and contraction of the fuel vapors pressures inside the tank.

 

Are you sure the Gen 3 Prius has a "plastic" fuel tank?

I clearly remember around the time of the Gen 3 release, Toyota defining the gas tank as being made out of what they called "resin". It raised a small red flag in my head.

Was hoping and I am hoping that this "resin" is as durable as any standard material used in manufacturing a fuel tank.

 

PA6 and HDPE are "plastics." Resin or polymers are fancy words for plastics.

I've been involved with the study of "plastics" for industrial and aerospace purposes for over 40 years.

Here's an interesting link I've found;

Low Permeability | European Plastic Automotive Fuel Systems

 

If you are smelling gas in the car, it might be coming from this cover plate's seal being compromised. Is the odor stronger in the back seat area as the cover is under the left rear seat:

 

Hmm...interesting.

My guess is Toyota probably chose to refer to the tank as being made out of a light weight "resin" as opposed to saying it was a Light Weight "plastic" thinking resin sounds more environmentally friendly.

In any case, I do hope this is not a problem that starts to arise with all Prius.