Has anyone replaced the gas tank and solved the pumping issue?

If I remember the whole story right, you had a thread you started back in June 2020 about a car you had just purchased and it had a problem with filling the tank. In that thread you were stepped through checking the components involved with onboard refueling, using Toyota tech docs that explain how damage to the system tends to result from overfilling or other nozzle tricks.




Following the Toyota docs, you had those parts replaced, and you reported as of 6 July 2020 that you were "confident to say the problem is resolved."

So far so good as of last July. However, in that same post where you reported the problem was resolved, you once again mentioned you had "topped it off". You had seen the Toyota literature explaining how topping off causes that problem, you had seen edthefox5 saying "for the love of god stop topping it off," and you were advised again after your "problem is resolved" post that "it might stay resolved even longer if you discontinue the topping-it-off practice."

Anyway, that was the end of that thread, way back in early July, and you weren't back again with this thread until February 17th. As of yesterday evening, you've reported that "the canister was replaced the other day" (unsurprisingly) and that it looks like you (once again) "have a normal pumping Prius now."

And you are still topping it off ....

 

Not sure that all of that effort was necessary......or useful......but that is the point I was trying to get across.

BUT.....there is more than one kind of "topping off".

If you leave the nozzle all the way IN and just run it until it clicks off a second time, you should be fine.
OTOH, if you pull the nozzle part way out and try to cram in the last drop.......that is the real definition of "topping off" and what causes the problem.

 

I'm not sure where one looks to find the "real definition" of topping off.

But many Prius owners put many trouble-free miles on their cars by following the simple practice of hanging the nozzle back up when it clicks off, putting the cap on and closing the door, paying for the gas, and driving away.

 

And once I found out how the automatic gas nozzles actually work, I have put on probably close to a million miles by letting it "click off" a second time while still in the neck. No problems doing that either.

The term "topping off" means "filling it to the top".
There is only one top.

 

Sometimes you run into people who found out how the automatic gas nozzles actually work long enough ago that it was before modern ORVR systems, and you can surprise them by telling them that their current car actually deliberately manipulates the pressure-sensitive nozzle to control when it shuts off.