Corolla to Prius gas tank swap

Thanks, I figured I’d go all out on this!

 

Corolla tank on the left 13.2 gallons. 660 mile range
Camry tank on the right 18.5 gallons 925 mile range

 

Well the plans for the Camry tank are getting scrapped. Decided to go with the corolla tank instead. The corners of the Camry tank would need to be beat to death with a hammer for enough clearance to fit and plus the tank covers the bolt holes for the mounting straps. So pretty much I would have to drill holes to make new mounts for the straps and I’m not gonna do that. Also I would have to cut the exhaust after the resonator and mount a new muffler in the tunnel under the center console cause there would be absolutely no room to run the exhaust to the back. Soo if you’re deciding to take on this project like I am just go with the 9th gen Corolla tank and not the Camry.

 

Wanted to add this as a reference. This is the stock Prius tank with all the emissions still attached to it.

 

Yes, the corolla tank makes the same contact points.

correct!

 

what year make and model is your parts car? I’ve read that thread. Don’t let those pics of the bladder tank intimidate you.

 

Well if you seriously want to swap your tank for a bladderless one you’ll need tank, sending unit, filler neck, straps and charcoal canister out of a 2003-2008 corolla to be a bolt in swap. Also if you can get your hands on the electrical harness inside the Prius tank it will be a complete plug and play from what I see. The Prius harness has a temperature sensor that makes the gas gauge accurate. You’ll have to cut a second gen gas tank open to get the harness. I got one out of the junkyard and used tin snips.

 

This is what you will need to do the swap. I still need to go back to the yard and get the exhaust heat shield for the tank.

 

The Matrix/corolla and vibe use the same emissions and gas tanks. I looked up the Prius c tank and it doesn’t look like it will work at all. The contact point on the body are totally different also.
I got everything I needed out of a 2005 Corolla.

Correct I am going to use the wiring harness that I cut out of the 2nd gen tank to make it a clean plug and play swap. All the emission sensors on the Corolla are the same as the Prius so the emissions wiring harness from the Prius can plug into everything on the Corolla charcoal canister.

The location of the corolla tank and access hole on the Prius are off by a few inches but the location of the corolla tanks fuel pump fits in the raised tunnel of the Prius under the seat.

The filler tube on the Prius is a metal flex tube and the corolla is a pre bent rubber hose. If you look at the drivers side wheel well on your Prius there is a notch cut out on the bottom front that is also in the same location on the Corolla and that’s where the filler tube goes through on the Corolla.

I’m going to use the stock Corolla sending unit because it’s calibrated to the depth of the Corolla tank to give an accurate reading for the gas gauge. Plus the harness that I cut out of the 2nd gen tank is a direct plug in for the Corolla fuel pump. Both the Prius fuel pump and the Corolla share the same 4 pin connector.

 

This is the harness I pulled out it the 2nd gen tank. Left side is the main plug for the harness, top right plug is for the fuel pump and bottom right plug is the temperature sensor. Plugs right into the Corolla fuel pump.

 

The Prius tank is definitely a lot heavier than the Corolla tank. The Corolla tank holds 1.3 gallons more than the Prius tank but is physically smaller. The Corolla tank is bladder-less, correct and plastic instead of metal.