2009 classic fuel tank issues but also gauge?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by tollkeen, Feb 25, 2026 at 11:27 AM.

  1. tollkeen

    tollkeen Junior Member

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    2009 Prius. Always had the classic fuel tank issues due to the bladder - lower capacity, certain pumps pumping too fast and clicking off immediately, seasonal variability in how successful gas pumping is. We always fill a bar or two before empty (before reading up about the bladder, we thought our gauge was just bad and we were always keeping tank half-full). This past week, gauge hit flashing empty on commute and I went for gas. Costco pump, started clicking immediately. I figured it surely needed at least a couple gallons, so I pumped in a few while fighting the constant clicks.

    But now, gauge is still flashing empty. Tried adding gas at several other stations over the space of a few days. Same issue, constant clicking, gauge still flashing empty. A few times the gas has actually seemingly gone all the way up the filler neck and started to come out, so it does seem to be near-full, whatever the capacity is.

    So, a couple questions. Is the only real fix to replace the whole $1500 assembly? I've seen posts about being able to slowly stretch the tank back out when warmer weather hits again. Second, is there a way to get the gauge working again without replacing the whole tank? I'm fine with limited capacity as long as it's at least like 5 or 6 gallons; we've dealt with that fine so far. I've tried the gauge reset instructions but had no luck.

    Also, is it worth $100 to get a diagnostic from the local dealer? Will they know any more?
     
  2. Tombukt2

    Tombukt2 Senior Member

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    Diagnostic ... No .so filling up till at neck like you can see it . Then going 300 miles and uhhh repeat ? No possible ?cannot remember to set trip?
     
  3. dolj

    dolj Senior Member

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    The bladder gets blamed a whole lot for these issues, but the same issues I read about on US cars with the bladder exist in cars without.

    Your issue is most likely a restricted ventilation pipe somewhere in the system. You will need a good mechanic well versed in the how the ORVR works.

    See this very good post by ChapmanF – Issue somewhere in the onboard refueling vapor recovery (ORVR) system.

    Also, the flashing gauge could be because there was a problem with the 12 V power supply. Check that your 12 V battery is fully charged then test its capacity. Auto parts store do that sometimes for free, in the hopes they can sell you a battery.

    I hope that helps.
     
  4. mr_guy_mann

    mr_guy_mann Senior Member

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    Most of the Gen 2 fuel tanks that I have replaced were done to correct fuel gauge problems. The level sensor inside gets worn and goes "open circuit" - which the dash gauge shows as 1 flashing bar.

    No, the whole tank assembly is sealed, and I don't know of any (reasonable) way to repair it.

    You can remove the rear seat base and access the fuel tank electrical connector to test sender resistance. It should read around 4 ohms "full" to 110 ohms "empty". If it is much higher (Kilo to Mega ohms), then it's bad.

    I believe it should be these two terminals (a brown and a black wire) prius%20tank%20conn.jpeg

    Posted via the PriusChat mobile app.