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Corolla to Prius gas tank swap

Discussion in 'Gen 2 Prius Technical Discussion' started by Rivieraman71, Mar 3, 2019.

  1. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    Mr. River A Man
    Sorry to see your headaches on install. I had hopes that the corolla fuel tank geometry could form and conform better to underside of Gen2

    Did or do all the evaporative hoses and charcoal canister connect okay
     
    #161 NortTexSalv04Prius, Jul 19, 2019
    Last edited: Jul 19, 2019
  2. Rivieraman71

    Rivieraman71 Active Member

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    Well the tank fits the bottom of the Prius floor perfect. The exhaust is going to have to be cut and rerouted and the Prius tank straps shortened and corolla filler neck lengthened. I didn’t attempt to try and route all the evap lines and take notes cause I had to have the car for work the next day and was kinda forced to throw it all back together.

    I’m moving to Oregon in October and will have to try this after I move. Then I will have more time to try and route evap lines, exhaust etc.
     
  3. Rivieraman71

    Rivieraman71 Active Member

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    BA94674B-63A6-4294-BC94-1F25AD1EC495.jpeg 414E3339-DE12-48C6-BCB5-C11F64E34E1C.jpeg 3341C330-4EE3-4389-A10A-62A6D11F2C47.jpeg Gas tank, charcoal canister and filler neck is all out and ready to start swapping in the Corolla parts 73D2E9FD-AB3C-4AFE-94B9-37EF0C48D389.jpeg E26CFCA9-A59A-476A-8F07-2CA554E82349.jpeg bladder less corolla tank is bolted in. Some adjustments on the straps and it will be in permanently. E9DC78B0-5B98-4256-A7C3-90F72CF39C25.jpeg Corolla Charcoal canister is bolted in.
     
  4. Dxta

    Dxta Senior Member

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    I have being wondering y we weren't getting updates any longer. I really want to see the end of this. Would be a better alternative for Prius tanks.
     
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  5. Rivieraman71

    Rivieraman71 Active Member

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    I had to wait till after I moved to tackle this again. Hopefully it will be done within the next few days. I still have a bit of work ahead of me.
     
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  6. SFO

    SFO Senior Member

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    In which part of the state did you unpack?
    Please document and take additional photos whenever possible.
     
  7. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    I was going to paraphrase and quote …. All about the journey and experience ….I am a Huge fan
     
  8. Rivieraman71

    Rivieraman71 Active Member

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    I moved to the Oregon coast and we are getting lots of rain which is making it fun to work in. I’ll try and document as much as possible.
     
  9. Rivieraman71

    Rivieraman71 Active Member

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    Thanks Tex. Getting ready to start wrenching again.
     
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  10. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    You had stated at one time the filler connection flex pipe may be short and exhaust may have to be manipulated (How is that part going) .The charcoal canister and evaporative lines are okay?
     
  11. Rivieraman71

    Rivieraman71 Active Member

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    I’m getting ready to cut the filler neck pipe now. It needs to be extended about 2 inches. I have an exhaust shop that will redo the exhaust for $80. The charcoal canister and Eve app lines look like they are going to be OK. I’m not sure if I like the mounting location that I have the charcoal canister I might try and move it.
     
  12. Rivieraman71

    Rivieraman71 Active Member

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    38BE2A8C-0B83-4463-A6F1-F911D3C788D6.jpeg The factory corolla fuel neck needs to be cut because it is too short and needs to be lengthened. I had to extend it about 3 inches. I went to the junkyard and got filler neck hose off of another vehicle. It must be rated for fuel or else the gas will eat through the rubber hose over time A7B0E305-F4EE-4727-A3C6-52ECBEDFA6C8.jpeg had to file all of the metal burrs off after I cut the neck. Definitely don’t want that going into the gas tank. 4E4298A3-874C-45A8-A32C-3BC9C0AA3BE5.jpeg 09C7C82F-0AF4-4874-B301-5165A9DEEE57.jpeg 4ED92F9A-E266-4763-8097-17C7411DC3C3.jpeg The fuel neck fits perfect. F55ECBED-2EB2-49B9-AAE4-4FE6D5CA6281.jpeg Using a factory mounting bolt for the tab on the filler neck. They line right up. 46E24AB6-5799-434F-BBA4-97A694626B8F.jpeg You won’t have to do this to your vehicle if it isn’t lowered. I was afraid of the axle hitting the charcoal canister so I had to bang in the spare tire well for the charcoal canister to clear the axle. EB36BA02-4F2E-4736-976C-F93C6F0F44BA.jpeg AC9FB106-D210-414F-B3D4-FA7610FB21CF.jpeg I used this factory mounting hole for the canister. It sits on the drivers side behind the rear bolt for the tank strap. C058BF40-5EA3-4F8F-8A9A-22298D9D1108.jpeg BD24CAD1-88BE-4D74-9500-2D8773926CCB.jpeg Canister clears the axle now. Surprisingly the spare tire well was easy to beat in with a hammer. If you have the factory suspension you won’t have to go do this step. I only did this because I have a lot of passengers in the vehicle sometimes and didn’t feel like hitting a pretty good pot hole and the axle coming in contact with the canister. It looked too close to call but I’d rather be safe than sorry. 5117CE4B-A938-4B17-9383-D377F2C28256.jpeg Mounting the canister here I didn’t have to extend any of the eve app lines. They fit perfect. 9088202A-B574-4539-9FA6-5143A41B260E.jpeg For the rear bracket I used a self tapping screw
     
    #172 Rivieraman71, Oct 18, 2019
    Last edited: Oct 18, 2019
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  13. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    Nice work …. refresh me..... charcoal cannister..... is not from the Prius Gen2 OEM however and equally important though from the 08 Corolla (Yes) …. Nice images...
     
    #173 NortTexSalv04Prius, Oct 18, 2019
    Last edited: Oct 19, 2019
  14. Rivieraman71

    Rivieraman71 Active Member

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    The charcoal canister is from a Corolla. I think a 2005. All the other parts are also from the same Corolla. Don’t let me taking a hammer to the spare tire well scare anyone from doing this swap. The spare tire still fits in there.
     
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  15. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    LMAO I am scared and Halloween is close by.....did you have to use all the Evaporative system from 05 Corolla
     
  16. Rivieraman71

    Rivieraman71 Active Member

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    Haha! What I took of the Corolla was the gas tank, fuel pump, Fuel line on the tank, fuel neck, charcoal canister and all the evap lines that went from the tank to the canister and the lines that are on the canister. OEM Prius parts that need to be used are the wiring harness inside the tank and wiring harness from outside the tank that was connected to the Prius emissions sensors. Ambient air temp sensor needs to be used for the gas gauge to be accurate and the other sensor I’m using from the Prius is the tank pressure sensor and the pressure switching valve.
     
  17. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    Nice and Huge SHOUT OUT
     
  18. Rivieraman71

    Rivieraman71 Active Member

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    Thanks Tex. Went to the junkyard today and got the heat shield for the gas tank.
     
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  19. 69shovlhed

    69shovlhed Surly tree hugger

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    I just noticed this. I been hating that stupid bladder for a decade. more pictures, please, and swap out that crap rear sway bar with an aftermarket bar or at least one from the corolla in the junk yard. its a 5 minute swap you'll love.
     
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  20. Rivieraman71

    Rivieraman71 Active Member

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    Yeah the bladder tank sucks in the cold weather. The Matrix sway bar fits too. The Prius one is pretty much tin foil lol.
     
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