I got to go to work here in a minute so I can't put too much on here for now but it is possible to do a Corolla fuel tank swap. I did it over the weekend and have put close to 300 miles on it and haven't had any significant issues. I'm still testing it out though to see if the gas gauge will read accurately after doing a reset and I'm going to run it dry a couple of times to see how it does. I am working on making a YouTube video to provide some in-depth information but I will make a small write up on here as well.
YouTube link of the information in more detail. First removed the tank. Over view of the system. Prep Corolla tank. Gut the junkyard tank for fittings, sensors, and wiring. In my video I go into more detail about this but I used an old Coleman propane tank for a vacuum manifold. With this I put the tank sensors associated with the bladder into it and this allows them to communicate with each other even though there is no "gas tank void" for it to monitor anymore. I used the Corolla tank straps. Used the gutted junk yard tanks filler pipe fitting so I could connect to the prius filler neck. Here is where I used the Corolla filter neck and connections to make the necessary bends and connections that I needed. Just showing how close the stuck exhaust is to the tank when installed. I was able to move a few things and create an air gap between the two. For those that are going to cry that it's too close... Cool I get it. Drive it over 800 miles and no signs of wear or burns. Jog on. This is the little whole I tucked the "clean air system" into. The harness I pulled from the junk yard tank to use as a conversion harness. In a nut shell that's how I did the swap. I did have a couple of check engine lights at the beginning. After I cleared them and sealed some leaks it did fine. Drove like this for a week and did have fuel gauge issues but that was because the sender unit from the yard was bad. Now the car has a 04-11 Camry tank in it and I'm going to see how that goes. Same process but did have to bend the rack ends to get the tank tucked up into the fuel cell cavity and cut the stock prius filler neck to connect the tank and filler neck. Also used the stock Camry exhaust because it needed the space.
I believe they are the same. Don't quote me. There is an old thread where someone attempted this but didn't finish it. I believe they said that the matrix was the same.
Could the Colman propane tank be replaced with a few brass pipe fittings screwed together, with only a few CC of volume inside? What is the minimum volume needed for the bladder logic to work, or at least not throw a code?
The only reason I use the Coleman tank was because it was readily accessible and I wasn't putting that much thought into it. The minimum volume from my point of view is not an issue that would arise with the way the system works. The only thing that really needs to happen is when the proper actuation for the system Diagnostics or tests occur they just need to happen at the rate at which they are functioning if that makes sense. Also the way that the vapor pressure sensor and the actuator module the fixes to the tank I needed something that would be at least the minimum size of opening for the rubber grommets from the tank to go into. Those are legitimately the only criteria that I was focusing on when choosing a "clean air tank system"
What about the actual carbon canisters - are they installed or did you delete those? Where does the fuel tank vent go? Posted via the PriusChat mobile app.
Appears the FWD 05-08 plastic Matrix Vibe tanks will fit. 03-04 FWD Matrix Vibe are steel and require some body work to fit from what I found online here. https://www.toyotanation.com/threads/07-gas-tank-swap-in-a-03.1699522/ Image below is 05 tank in 03 Corolla.
What is the problem with using a Gen 3 Prius tank for this sort of conversion? It will still need all the modifications to fake out the bladder hosing/circuitry, but one might expect that the connection for the fill and breather tubes would be pretty close to that on a Gen 2 tank, and in terms of size, it should be close too. It is only a 12 gallon tank, but I for one would be just fine with that size tank since I can already drive LA to San Jose on a single tank of gas (without a lot to spare) with the current bladder tank, and this would provide at least another 100 miles range.
Underside unibody design might be different, so like surface contour and mounting points for the straps. Hole location for the fuel pump might be different location as well. I'll have to take a look when I see a gen 3 in the yard again, as I get into the interchange stuff since is super neat to rescue more good parts and good to have more options when can. If I am recalling correct, about the only thing from the gen 3 and later models are the ball joints that interchange. Now that I think about more, the antenna, 9006 bulbs can be used for fog lights, might be some other bulbs, wipers if you want, 5x100 rims do, HV battery modules and 12V battery. I was wondering about the inverter pumps hacking from a gen 3 to a gen 2, though haven't studied enough to determine feasibility.
