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"
