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Corolla to Prius gas tank swap

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

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  1. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    FYI
    semi drop on Corolla fuel tank

     
    #61 NortTexSalv04Prius, Apr 6, 2019
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  2. Rivieraman71

    Rivieraman71 Active Member

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    Thanks for the video! Was watching it when I researching the swap and definitely helped a lot on the decision to do the swap.
     
    #62 Rivieraman71, Apr 8, 2019
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  3. NortTexSalv04Prius

    NortTexSalv04Prius Active Member

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    Hey I also found the following YouTube post semi drop of a Gen 3 Prius fuel tank wondering (curious) if that could be adapted to a Gen 2
     
    #63 NortTexSalv04Prius, Apr 13, 2019
  4. Rivieraman71

    Rivieraman71 Active Member

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    I was looking at a 3rd gen swap too and I think the corolla will be more straightforward. It’s pretty much plug and play with just a few emissions hoses being rerouted.
     
    #64 Rivieraman71, Apr 16, 2019
  5. terramir

    terramir Member

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    I have always thought it was a pain in the arse to fill the prius tank, however I get my tank full the most I ever put in it is about 11.5-11.6g myself so I was running on fumes basically. I have to top off the last gallon to gallon and a half but I get the tank full maybe my bladder is just stretched so far that it dun matter it's 16 years old after all (reg 1st 10/2003). but A tank with a 13+ gal capacity where I dun have to top off the last gallon to 1 1/2 gal would be cool.

    terramir
     
    #65 terramir, Apr 16, 2019
  6. Rivieraman71

    Rivieraman71 Active Member

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    Went to the junkyard and got everything I need for the gas tank swap. They were having a 50% off sale today and walked away with everything for $59 out the door.
     

    Attached Files:

    #66 Rivieraman71, Apr 20, 2019
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  7. TMR-JWAP

    TMR-JWAP Senior Member

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    Out of curiosity, is it at all possible to just remove the bladder through an opening? Perhaps remove any components from the top of the tank and just cut it out?
     
    #67 TMR-JWAP, Apr 20, 2019
  8. Rivieraman71

    Rivieraman71 Active Member

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    You have to cut the tank open to remove the bladder. I wish it was that simple. Took me about 2 hrs to get everything out at the yard.
     
    #68 Rivieraman71, Apr 20, 2019
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  9. padroo

    padroo Senior Member

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    Working under a car at a junk yard sucks. I feel for you.:cry:
     
    #69 padroo, Apr 20, 2019
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  10. Rivieraman71

    Rivieraman71 Active Member

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    All I thought was “I hope this car doesn’t fall and kill me” lol
     
    #70 Rivieraman71, Apr 20, 2019
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  11. Raytheeagle

    Raytheeagle Senior Member

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    Hopefully it had more than a couple of steelies holding it up;).

    Otherwise I hope the straps weren’t too tight causing you to have to torque on it(y).
     
    #71 Raytheeagle, Apr 20, 2019
  12. Rivieraman71

    Rivieraman71 Active Member

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    2 steelies holding the front and 1 holding the back. It was a little nerve racking breaking bolts loose underneath.
     
    #72 Rivieraman71, Apr 20, 2019
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  13. Raytheeagle

    Raytheeagle Senior Member

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    You’re a brave man;).

    Or maybe just desperate :cool:.

    But at least you lived to tell the tale(y).
     
    #73 Raytheeagle, Apr 20, 2019
  14. Rivieraman71

    Rivieraman71 Active Member

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    A little bit of both lol
     
    #74 Rivieraman71, Apr 20, 2019
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  15. Rivieraman71

    Rivieraman71 Active Member

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    726B229C-B6FC-4669-AAC7-E20D1073262F.jpeg So plans have changed on the corolla gas tank swap. It’s now going to be a Camry tank going into the Prius. Why bump up to a 13.2 gallon tank when you can go all out and have a 18.5 gallon tank in a Prius! Went back to the junkyard and dropped the tank in a 2007 Prius and a 2005 Camry. Shoved the Camry tank in there and it’s gonna need a little persuasion with a block of wood and a hammer but it’s pretty close to fitting in there. Here’s a pic after putting the Camry tank in place of the Prius tank. Now mind you there are no straps holding it in it’s just wedged in there. It has about a good 3 inches of space above it that it needs to go up and and inch or 2 forward. Will have a 900 mile range after the swap is done. And can you say no more pain in the rear bladder?
     
    #75 Rivieraman71, Apr 23, 2019
    Last edited: Apr 23, 2019
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  16. padroo

    padroo Senior Member

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    I always hated a weak bladder.:D

    Good luck on your project and be safe under those old cars.
     
    #76 padroo, Apr 23, 2019
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  17. Rivieraman71

    Rivieraman71 Active Member

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    Thanks, safety first! Going back tomorrow to grab the tank.
     
    #77 Rivieraman71, Apr 23, 2019
  18. TMR-JWAP

    TMR-JWAP Senior Member

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    This is where I'm confused. I've always thought fuel tanks were designed for specific car bodies due to fit and form to ensure the tank top matches the contours of the car floor. How can there not be significant interference issues between the top components and places on the car body? What do you do if a high pressure fuel supply line or return line rubs on the car body and eventually springs a leak? I guess I'm just not getting 'it'. Or do you just jam it up there and crank down on the straps and assume it's all good? Then it's just a matter of keeping your fingers crossed that it doesn't fireball at some point?

    Why not just cut open a Prius tank and remove the bladder if desired. Find another tank and cut a 2 or 3 inch strip from the circumference and weld it onto the first tank. Now the tank would be 2 or 3 inches deeper, but would still have the OEM top components and shape.

    Hell, idk what I would do with that kind of range anyway. Gotta stop for snacks and restroom breaks anyway...
     
    #78 TMR-JWAP, Apr 23, 2019
  19. Rivieraman71

    Rivieraman71 Active Member

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    The contours of the top of both tanks is very similar. The tank shape allows for the fuel lines to be safely routed on top of the tank. When I dropped the Prius tank I looked to see what sat on top of the tank and took that into consideration. I definitely wouldn’t just bolt it in and hope it worked. I’m aiming to make it look like a factory job. If it doesn’t work I have the corolla tank that will fit with no modifications to the tank itself. It’s pretty much a challenge to see if it can be done and help others that might want to tackle the same project.
     
    #79 Rivieraman71, Apr 23, 2019
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  20. Rivieraman71

    Rivieraman71 Active Member

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    CC22765B-4292-4376-BEF0-DA87025729C4.jpeg C4ACD232-C3FB-43A4-BE41-D054D38C264E.jpeg View attachment 169987
    The contours of the tanks are almost the same on top. The Electrical connection for the Prius sending unit and the sending unit on the Camry tank line up in the same spot at the access hole under the seat.
     
    #80 Rivieraman71, Apr 23, 2019
    Last edited: Apr 23, 2019
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