Parts fuel tank, how to test capacity before install?

Discussion in 'Gen 2 Prius Technical Discussion' started by foreverPriusCar, May 13, 2026 at 12:41 AM.

  1. PriusCamper

    PriusCamper Senior Member

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    Yes, because they look for Toyota logo on stamp of cat and nothign else to fail an inspection... And if they look back where gas tank is we've no idea what they'll be looking for but when talking about a 2004-09 Prius I'm near certain a gas tank assembly from a different model of Toyota will not pass that inspection. But would love to be proved wrong!
     
  2. Tombukt2

    Tombukt2 Senior Member

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    They'd have to have an idea that the gas tank is wrong? I'm gonna do my best to make it not so. Or look not so . Etc .
     
  3. mr_guy_mann

    mr_guy_mann Senior Member

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    Nope, it's not just a pressure sensor. The later system uses a small pump to pull a slight vacuum on the tank "void" space and canister, and the ECM is looking for a pressure change consistent with that air volume.

    It also vents the evap thru the purge solenoid and looks for another pressure change. Then checks for fuel leaks from the bladder.

    Short form is the ECM is testing the entire SYSTEM, and the amount of jerry rigging needed to fool it would outweigh any gains from using the wrong fuel tank.

    Posted via the PriusChat mobile app.
     
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  4. Tombukt2

    Tombukt2 Senior Member

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    So with the pressure sensor inside yeti cup when the pump comes on to alter the pressure because the fuel is missing inside tank . So pump comes on to fill or sux the the space in tank the press in yeti cup changes too . The sensor do its job for such .. I'm not in California so if all this is going to put a light on because of some pressure not correct on a sensor . This will not affect my inspection in North Carolina or anything as old as car us I can burn or remove bulb. There's a push here now to remove emissions from the whole state and it's probably going to pass.
     
  5. Mendel Leisk

    Mendel Leisk MMX GEN III

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    What’s a “yeti cup”?
     
  6. Tombukt2

    Tombukt2 Senior Member

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    You know those stupid things that the young urban pros front coffee out of . They also make expensive coolers the things you add ice to and bears aren't supposed to be able to get into when out in woods . They advertise their on TV ETC
     
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  7. foreverPriusCar

    foreverPriusCar New Member

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    Okay, so I picked up the used tank yesterday. Here's my plan for the install. Washout with warm water and dish soap. Drain. Air dry for a few days. Install. Fill up with a couple of gallons of gas. Drive.

    Does that sound right? Do I even need to clean it out since the Prius tank is well sealed? Should I run a fuel system cleaning additive? Should I transfer my hoses and stuff to the used tank if it already has it in place?

    TIA!

    EDIT: Removal was fairly straight forward. Install shouldn't be an issue either. Car was sitting in the salvage yard for 5 months after an accident took it off the road.
     
    #27 foreverPriusCar, May 17, 2026 at 12:38 PM
    Last edited: May 17, 2026 at 2:01 PM
  8. Tombukt2

    Tombukt2 Senior Member

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    You want to clean the tank out with anything but water-based solutions like Stoddard solution is what they use it to dry cleaners you but it 2 gallons to slush around in they're . You're not going to be removing too much stuff . You got to be careful doing this if you get too much stuff loose in the tank large pieces of flakey material won't come out orfices . Remember you have no real access to this tank internally. So if anything rather than upsetting and disturbing what's in the tank that's laying down matted against the metal bottom and edges of the tank
     
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  9. Tombukt2

    Tombukt2 Senior Member

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    This is why the Corolla tank is looking better by the minute luckily I haven't had to change any gas tanks fuel pumps or any of that in any Prius. One fuel pump in a gen3 45 min job 40 pump
     
  10. Tombukt2

    Tombukt2 Senior Member

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    But now all my cars are at 500K so next is probably a EFI pump . At that point I will want a tank I can open up
     
  11. foreverPriusCar

    foreverPriusCar New Member

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    One last thing. I'm doing a few tank rundown tests before swapping the tanks. What I did yesterday was drive 400 miles as that's what my estimated 3/4 empty range would be averaging 45mpg at 8.4ish gallons. When I hit the 400 miles, I pulled into a gas station, found levelish ground and reset my fuel inclination sensor, and then filled up 7.8 gallons. At a difference of 0.6 gallons I'm not too bothered. Before the reset my gauge would jump down to three blips at 200 miles. Currently, post reset, it's running more inline with what one would expect -- not erratically. I'm going to do a few more rundown tests to see how the fuel gauge looks and how much I can fuel up to see if it's absolutely necessary to swap the tanks.
     
  12. mr_guy_mann

    mr_guy_mann Senior Member

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    That's actually a good question. Why are you considering a replacement tank? I have only done this for faulty level sensors or rust damage.

    And yes, I would NEVER put any water based substance in the tank (bladder).

    Posted via the PriusChat mobile app.
     
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  13. foreverPriusCar

    foreverPriusCar New Member

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    Mainly panic and hysteria. lol. Now that I'm running through some tests to get data for me to judge the need, that panic and hysteria is subsiding. I jumped on the fuel tank at $60 because online it's closer to $150-300 for a used tank. If I end up needing to swap, I'll have it in the garage if not I can sell it for parts
     
    #33 foreverPriusCar, May 18, 2026 at 9:55 PM
    Last edited: May 18, 2026 at 10:00 PM