Corolla to Prius gas tank swap

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

  1. Dxta

    Dxta Senior Member

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    I can see you got an aftermarket coil to raised the ground clearance height? The rear of the car seems to me would be too high?
     
  2. Rivieraman71

    Rivieraman71 Active Member

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    The car is dropped an inch on Tanabe springs. She sits pretty low. It’s on jack stands and there’s no weight on the suspension in the pics and that’s why it looks high. 9FD5646F-4814-4097-B54B-95A8423C67A3.jpeg 22C9886F-A031-4FBE-940D-430E8DED2CB3.jpeg If I have people sitting in the back it squats so that’s why I beat the tire well in so the axle wouldn’t hit the charcoal canister when I hit bumps.
     
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  3. Rivieraman71

    Rivieraman71 Active Member

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    Will be working on lengthening the wiring harness today and routing the fuel lines. I don’t know if I’ll have the tank permanently in today I’m still figuring out the rubber spacers and where to put them.
     
  4. Rivieraman71

    Rivieraman71 Active Member

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    614A9DD9-D2F6-4CCE-85BF-AE412FEBF929.jpeg On the wiring harness the only plug that needed to be lengthened was the plug for the pump module 662AE848-346A-4811-8127-D0CC96B4009B.jpeg E9F4960D-2531-478B-93B5-B47AAC7AC808.jpeg Plug for the pump module was lengthened about a foot. I used dielectric grease and shrink wrap to keep my connections as water tight as possible.
     
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  5. Dxta

    Dxta Senior Member

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    My guts tells me this project would work. This would be a big breakthrough in tackling that stupid bladder tank.
     
  6. Rivieraman71

    Rivieraman71 Active Member

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    My friend asked me what if it doesn’t work after everything you’ve done, just put it all back together? Nope, I’m gonna set it on fire lol
     
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  7. Rivieraman71

    Rivieraman71 Active Member

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    0465A166-31C2-4F9D-8EE2-FF251BEF9B58.jpeg 76968B08-2933-431E-946A-C323DBCA82CC.jpeg This is the harness inside of the Prius tank. Only way to get it out is to cut the tank open. 96129E62-BDAF-4DEF-8E1D-6314C63A788B.jpeg Fuel pump end C6868665-F977-4751-99F9-5F610A196F74.jpeg ambient air temp sensor 94CF0768-8A94-449B-B054-81D0A5AB5AF1.jpeg fuel tank pressure sensor. Just leave this laying on top of the tank. Don’t try and plumb it in to read anything. It’s just to detect if there is a leak in the bladder. If it reads any pressure it will throw a code. D0BE7F4F-5232-4B5E-B82B-756F7572DA80.jpeg Pressure switching valve end C837CCA1-A13C-4290-B5A8-48E431C85736.jpeg pump module. This is the one that needed to be lengthened. 11A12199-67E0-4A26-88D4-31859B88228B.jpeg 4827D674-5CBC-420C-A019-99C5DDA367B3.jpeg corolla fuel line E5368862-2D59-4BC2-AB9B-334BAFE4F15B.jpeg Prius purge valve line AEDB31A6-0FA2-488A-B08B-22F5F0CA7231.jpeg purge valve line goes to the bottom hard line. AFC717FD-D309-4D24-AD20-913C02A64622.jpeg 772A1848-544D-466A-BE60-6617472DE5FA.jpeg 1/4 inch fuel line that will run to the pressure valve
     
    #187 Rivieraman71, Oct 21, 2019
    Last edited: Oct 21, 2019
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  8. Rivieraman71

    Rivieraman71 Active Member

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    I bought some rubber spacers from Home Depot to use for between the gas tank and the body and they didn’t work at all. I ordered jumbo 3.5 inch pool noodles that will work perfect but they won’t be here till Friday. I might post a few more pics tonight but after that I get a nice break from laying under this thing.
     
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  9. Rivieraman71

    Rivieraman71 Active Member

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    So... update. It starts and runs but the car definitely isn’t happy! Idles but it’s a low idle and when the engine shuts off if I hit the gas it won’t come back on. I’ll shut the car off and start it back up. It does the same thing. Idles low for a few seconds and shuts off and the ice won’t kick back on when I hit the gas. Plus after the engine shuts off I hear the hybrid system click in the back as if it’s shutting down. Triangle of death, engine light and vsv light is on. On the consumption screen there’s only one bar and it’s purple and a picture of a car with an explanation mark in the middle in the top left hand corner.

    Only thing I can think of is I don’t think I have a good ground on the fuel pump. The bolt that the ground wire is on hangs down and the ground terminal is pretty much held on by it hanging on the threads. I couldn’t find a nut with the right thread to hold the ground. I’ll try and get the right nut tomorrow and get a good ground. Hopefully this fixes the issue.
     
    #189 Rivieraman71, Oct 21, 2019
    Last edited: Oct 21, 2019
  10. Rivieraman71

    Rivieraman71 Active Member

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    So unfortunately this was a bust. Maybe a retune on the computer would solve the issue. Maybe the hybrid is low and causing all of the issues. Since the engine will only run after initial start up and that’s all it will do I don’t want to drain the hybrid to the point the car won’t start. Car is 11 yrs old and original battery so I don’t want to stress it. Prius tank is going back in and I’ll just have to live with the bladder tank. Don’t know until you try I guess. This makes me question if a Canadian model tank would work. Oh well, still love the car. Just have to live with the quirky gas tank.
     
  11. bisco

    bisco cookie crumbler

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    great missionary work man!

    you took one for the team. win or lose, we appreciate the effort. (y)
     
  12. Prodigyplace

    Prodigyplace Senior Member

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    Perhaps @Mendel Leisk or @Tideland Prius could export one for you?
     
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  13. Rivieraman71

    Rivieraman71 Active Member

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    Thanks man! It was definitely an adventure even though it didn’t work out. I’m leaving the battery connected so it saves the codes. Going down to oreillys so they can read them. Definitely curious as to what codes were thrown.
     
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  14. Rivieraman71

    Rivieraman71 Active Member

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    Thanks man! It was definitely an adventure even though it didn’t work out. I’m leaving the battery connected so it saves the codes. Going down to oreillys so they can read them. Definitely curious as to what codes were thrown.
     
  15. bisco

    bisco cookie crumbler

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    i can't believe you accomplished all that without tech stream
     
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  16. spdracrm3

    spdracrm3 New Member

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    anybody know if Canada got the bladder tanks ? maybe like Europe they dont use the bladder system and could be a closer source ?. ive lost 100 miles range in my 04 recently as it gets cold and its the only frustrating thing about the car ,hate the bladder guessometer tank
     
  17. Rivieraman71

    Rivieraman71 Active Member

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    Canada had bladderless tanks as far as I know.
     
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  18. Mendel Leisk

    Mendel Leisk Titanic Social Director

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    I believe Canadian 2nd gen do have the bladder tank? Not sure though.
     
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  19. Rivieraman71

    Rivieraman71 Active Member

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    I wish I had a reader that had live stream or tech stream. Could have read the live data and see exactly what was going on.
     
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  20. Rivieraman71

    Rivieraman71 Active Member

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    It definitely seems like it was a computer communication issue
     
    #200 Rivieraman71, Oct 22, 2019
    Last edited: Oct 22, 2019
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