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LA TImes covers fuel tank bladder issue

Discussion in 'Gen 2 Prius Main Forum' started by KTPhil, Mar 27, 2009.

  1. KTPhil

    KTPhil Active Member

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    http://www.latimes.com/business/la-fi-prius26-2009mar26,0,6623608.story

    From the Los Angeles Times
    2010 Prius to have rigid gas tank instead of fuel bladder
    Toyota drops the Earth-friendly collapsible bladder because of user complaints.

    By Martin Zimmerman
    March 26, 2009

    When the next-generation Toyota Prius hits dealer showrooms in late May, it will come with a bigger engine, better fuel economy and solar-powered cabin cooling.

    What it won't have is the innovative "fuel bladder" that has served as the Prius' gas tank since the Japanese-built hybrid first landed on these shores almost nine years ago.

    Toyota decided to ditch the environmentally friendly bladder in part because some Prius owners complained that the collapsible container held much less fuel than the 11.9-gallon capacity listed in the owners' manual -- taking a big bite out of the car's range between fill-ups. In a related issue, some owners said the flexible tank's fuel gauge tended to signal prematurely that the tank was close to empty.

    The new 2010 Prius -- the third generation of the groundbreaking gas-electric hybrid -- will use a rigid tank made of a lightweight resin rather than the bladder.

    "The chief reason was because one of the sore points with the current-generation Prius" dealt with the fuel tank and gauge, Toyota spokesman Bill Kwong said.

    The change is coming too late for Darlene Sharar, an engineering technician who lives in rural Washington and often drives in areas where gas stations are few and far between.

    "In any other car I've owned, I know a tank of gas will get me 'X' number of miles," said Sharar, adding that she often could pump no more than seven gallons of gas into her 2008 Prius, even when the fuel gauge was flashing "empty."

    "Instead of a range of 500 miles, I've got a range of 300 miles," she said. (The Prius gets 46 miles per gallon in combined city-highway driving, according to government figures.)

    Attempts to get Toyota to resolve the issue were unsuccessful, she said. In an e-mail to Sharar, a Toyota customer service representative said the issue involved "the design of the fuel tank and there is no repair available to change the design."

    Sharar eventually traded the Prius in for a new 2009 Toyota Camry.

    The automaker blames the problem in part on temperature changes. The Prius owners' manual notes that the capacity of the fuel bladder drops by about 1.3 gallons at 14 degrees Fahrenheit.

    As for the fuel gauge, maintenance manuals say recalibrating it can sometimes solve the problem.

    Owners with a fuel-bladder problem usually complain that the tank won't take more than 9 1/2 or 10 gallons of gasoline, Kwong said.

    "I've never heard of only being able to get seven gallons" into the bladder, as Sharar contends, Kwong said.

    Fuel bladders, common in airplanes and racing vehicles, are a rarity in commercial passenger cars, which typically use rigid tanks made of high-density plastic, said Craig Hoff, professor of mechanical engineering at Kettering University in Flint, Mich. By collapsing as fuel is pumped to the engine, bladders help prevent fuel vapor from building up in the tank, thereby reducing hydrocarbon emissions.

    The Prius' new fuel tank will use an improved vapor-recovery system that will allow the car to retain its low-emission rating from California regulators, Kwong said.

    [email protected]
     
  2. wicastawakan

    wicastawakan New Member

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    Don't get me wrong, I don't really like the bladder thing, but it is really not all that big of a problem for me. I can get enough fuel in the tank without going through a bunch of gyrations to get me 450 miles or so. Believe me, I'm ready to take a break & don't mind filling up again.

    I don't worry about how many gallons the book says it holds, I don't worry about how many gallons I get in, I just "fill it up", chug down the road anywhere from 400-500 miles. I do not plan on running out of gas.

    I have always had a motto that it costs no more to keep the top half of the tank full than it does the bottom half full. I work in the medical field & most of my family live out of state, so I am always prepared. Being a pilot, the other plus is less inclination for condensation with a full tank (most vehicles do not have a bladder).

    How in the heck could this ever make the NYTimes is beyond me.....
     
  3. KK6PD

    KK6PD _ . _ . / _ _ . _

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    I get 8 Gal. every time I fill up. Equates to 400 miles traveled...

    This was just a filler story for LA Times because they could not sell the paper space with a couple more crappy ad's!

    Lets beat this to death some more!!!
     
  4. KTPhil

    KTPhil Active Member

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    LA Times, not NY Times.

    It may be filler, but it is the first article (of the admittedly few I've read) that had a direct citation of the problem from Toyota itself.
     
  5. usbseawolf2000

    usbseawolf2000 HSD PhD

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    The bladder tank was improved starting from 06 model.
     
  6. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Highlander Hybrid and Camry Hybrid have a better (but more complex) fuel tank design where a pump is used to control gasoline vapor emissions. There's no problem filling the tank with these vehicles. This design was most likely adopted for the 2010 Prius.
     
  7. JayGoldstein

    JayGoldstein Member

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    What were the improvements? I recently had three consecutive "fill-ups" which only registered 9 bars. :confused: FWIW, the technique I always use when I pump gas is to let pump run for one click after the automatic shut off.
     
  8. DHardy

    DHardy New Member

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    Yeah I'm completely new to the Prius (almost 3 weeks since I got mine) and last night my tank (I guess I should say bladder instead) was at 3 bars so I took it in to fill up the tank. It originally only allowed me to put in an additional 2 gallons into the Pirus. I had to keep putting the pump nozzle in and out of the bladder's intake to be able to squeeze in another 3 gallons altogether. After starting up, the tank gauge showed full bars, then after 30 seconds, one bar short of full. Yes, it was cold (32 f), but is this normal?
     
  9. Genoz World

    Genoz World ZEN-style living

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    This issue has been beat to death! But, it is a nuisance..... especially when i am traveling long distances.
     
  10. Frayadjacent

    Frayadjacent Resident Conservative

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    I'm new to the Prius myself, and have read the lamentations of the fuel bladder, so I've prepared myself for the eventuality that I will only get about 350 -400 miles before I 'should' fill up again.

    One thing I'll be doing to mitigate the risk is to use a fuel economy tracking site (mymilemarker.com) that will plot out an average fuel economy over fillups. Given the tank issues, the fuel economy for each tank may end up being off by a bit, but over many tanks, it should average out. From that, it will be easy to figure out how much range I should have and not overdo it.
     
  11. Celtic Blue

    Celtic Blue New Member

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    What were the improvements because they don't seem to have worked?

    I can still rarely get 9 gallons into it from the flashing pip. I've succeeded in doing so only twice so far and one of those came from continuing to pump gas until it clicked off about 4 times.

    It was the first time I had done more than one click. The pump was one I had used a time or to before but this time it was sensitive to line pressure, whenever someone else's pump kicked off, mine would click off as well...even at only 5-6 gallons or so which was ridiculous, so I kept cautiously adding as it kicked off at 7 and 8 gallons until I was sure it was full.
     
  12. usbseawolf2000

    usbseawolf2000 HSD PhD

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    I can't find the document that has the list of improvements in the 06 model. I think the improvement was made to show the pips more accurately. For me, when I fill up after the flashing pip, I can get 9 gallons. I have gone 50 miles over and got 10 gallons a few times.

    I think there were reports of 05 and 04 models running out of gas shortly after the flashing pip. The improvement was probably to eliminate that issue but not to allow more gas in the tank/bladder.

    I will continue to look for that document. If I find it, I will post it. It seems no one else has a copy of it.
     
  13. SageBrush

    SageBrush Senior Member

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    The fuel pump handles in my area of the world have two flow rate settings. I use the slower one, and am rarely unable to pump in about 9 gallons starting from the flashing pip. Over the past 4+ years I remember twice having to fiddle manually with the pump's fuel rate to coax the bladder into filling up.
     
  14. Patrick Wong

    Patrick Wong DIY Enthusiast

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    I've attached a copy of the 2006 New Car Features Manual, pages 2 - 5. I am not aware that any changes were made to the 2G fuel tank system.
     

    Attached Files:

  15. usbseawolf2000

    usbseawolf2000 HSD PhD

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    Patrick,

    I must have remember incorrectly. EVAP control system was improved, not the entire fuel system.

    Do you have the next page showing improvement in the traction control? It should be under ECU section.
     
  16. daniel

    daniel Cat Lovers Against the Bomb

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    I drive an early 2004 (delivered in January, 2004). The fuel fill thing is a nuisance, but only a minor one. I rarely get more than 7 gallons in if I'm down to one pip. I can easily drive 300 miles and have lots of reserve (i.e. I can begin looking for a station after 300 miles) and I'll tell you that after 300 miles of driving I need to stop and stretch my legs!

    The woman in the article who complained that 300 miles was not enough says she lives in rural WA. The entire state is only slightly more than 300 miles across. It's just not that big a deal to stop for gas once in a trip all the way across the state. On a long trip, I generally fill up long before the tank is low, just because I need a rest.
     
  17. Celtic Blue

    Celtic Blue New Member

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    On a long trip I don't want to stop until it is time to eat. If it is under 500 miles, I don't want to stop until I reach the destination.

    And in Winter or wet weather I want to keep the number of fills to the absolute minimum. So you are welcome to stop every 300 miles or less if you like, but I would prefer to use a normal amount of the tank's capacity and reduce the number of stops I must make.
     
  18. qbee42

    qbee42 My other car is a boat

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    I like to stop more often. It's better for your concentration and your health. At the very least we stop to use the bathroom. Even using a conservative eight usable gallons and 40 mpg, that makes for 4.5 hours between fill-ups at highway speed. I don't like to drive longer than that, nor do I go longer than that without eating if I can help it. Obviously some people are tougher than others.

    Tom
     
  19. northrk

    northrk Junior Member

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    Given that they have changed the tank for 2010, does this now mean they will provide DTE (Distance To Empty) info in miles? All of my cars/truck since the 80s have had this.
     
  20. qbee42

    qbee42 My other car is a boat

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    Yes, the 2010 has it. I have seen it with my own eyes.

    Tom