Corolla to Prius gas tank swap

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.

 

Gas tank, charcoal canister and filler neck is all out and ready to start swapping in the Corolla parts bladder less corolla tank is bolted in. Some adjustments on the straps and it will be in permanently. Corolla Charcoal canister is bolted in.

 

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.

 

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.

 

Thanks Tex. Getting ready to start wrenching again.

 

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.

 

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 had to file all of the metal burrs off after I cut the neck. Definitely don’t want that going into the gas tank. The fuel neck fits perfect. Using a factory mounting bolt for the tab on the filler neck. They line right up. 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. I used this factory mounting hole for the canister. It sits on the drivers side behind the rear bolt for the tank strap. 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. Mounting the canister here I didn’t have to extend any of the eve app lines. They fit perfect. For the rear bracket I used a self tapping screw

 

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.

 

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.

 

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

 

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