Corolla to Prius gas tank swap

The car is dropped an inch on Tanabe springs. She sits pretty low. It’s on jack stands and there’s no weight on the suspension in the pics and that’s why it looks high. If I have people sitting in the back it squats so that’s why I beat the tire well in so the axle wouldn’t hit the charcoal canister when I hit bumps.

 

Will be working on lengthening the wiring harness today and routing the fuel lines. I don’t know if I’ll have the tank permanently in today I’m still figuring out the rubber spacers and where to put them.

 

On the wiring harness the only plug that needed to be lengthened was the plug for the pump module Plug for the pump module was lengthened about a foot. I used dielectric grease and shrink wrap to keep my connections as water tight as possible.

 

My friend asked me what if it doesn’t work after everything you’ve done, just put it all back together? Nope, I’m gonna set it on fire lol

 

This is the harness inside of the Prius tank. Only way to get it out is to cut the tank open. Fuel pump end ambient air temp sensor fuel tank pressure sensor. Just leave this laying on top of the tank. Don’t try and plumb it in to read anything. It’s just to detect if there is a leak in the bladder. If it reads any pressure it will throw a code. Pressure switching valve end pump module. This is the one that needed to be lengthened. corolla fuel line Prius purge valve line purge valve line goes to the bottom hard line. 1/4 inch fuel line that will run to the pressure valve

 

I bought some rubber spacers from Home Depot to use for between the gas tank and the body and they didn’t work at all. I ordered jumbo 3.5 inch pool noodles that will work perfect but they won’t be here till Friday. I might post a few more pics tonight but after that I get a nice break from laying under this thing.

 

So... update. It starts and runs but the car definitely isn’t happy! Idles but it’s a low idle and when the engine shuts off if I hit the gas it won’t come back on. I’ll shut the car off and start it back up. It does the same thing. Idles low for a few seconds and shuts off and the ice won’t kick back on when I hit the gas. Plus after the engine shuts off I hear the hybrid system click in the back as if it’s shutting down. Triangle of death, engine light and vsv light is on. On the consumption screen there’s only one bar and it’s purple and a picture of a car with an explanation mark in the middle in the top left hand corner.

Only thing I can think of is I don’t think I have a good ground on the fuel pump. The bolt that the ground wire is on hangs down and the ground terminal is pretty much held on by it hanging on the threads. I couldn’t find a nut with the right thread to hold the ground. I’ll try and get the right nut tomorrow and get a good ground. Hopefully this fixes the issue.

 

So unfortunately this was a bust. Maybe a retune on the computer would solve the issue. Maybe the hybrid is low and causing all of the issues. Since the engine will only run after initial start up and that’s all it will do I don’t want to drain the hybrid to the point the car won’t start. Car is 11 yrs old and original battery so I don’t want to stress it. Prius tank is going back in and I’ll just have to live with the bladder tank. Don’t know until you try I guess. This makes me question if a Canadian model tank would work. Oh well, still love the car. Just have to live with the quirky gas tank.

 

Thanks man! It was definitely an adventure even though it didn’t work out. I’m leaving the battery connected so it saves the codes. Going down to oreillys so they can read them. Definitely curious as to what codes were thrown.

 

Thanks man! It was definitely an adventure even though it didn’t work out. I’m leaving the battery connected so it saves the codes. Going down to oreillys so they can read them. Definitely curious as to what codes were thrown.

 

Canada had bladderless tanks as far as I know.

 

I wish I had a reader that had live stream or tech stream. Could have read the live data and see exactly what was going on.

 

It definitely seems like it was a computer communication issue