Tank Mounting Problems of Toyota Corolla

Filled gas tank as usual. On leaving gas station heard clanking noise. Went home and thought something was loose in my trunk. Checked- nothing was. My husband went under the car and found the heat shield for the gas tank loose. The next day I brought it to my mechanic. He had to replace the gas tank hanger. The plastic where they put the bolt had split apart. The bolt was broken in half and rusted. The new gas tank hanger has a completely different design so I am sure Toyota is aware of this problem and as usual is being very "quiet". This was an expensive repair for me. Toyota should have had a better way to secure the gas tank and heat shield.

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The contact owns a 2008 Toyota Corolla. While driving approximately 35 mph, there was a loud banging noise outside of the vehicle. The contact stated the front end of the fuel tank shield partially detached due to a loose bolt which completely rusted. The contact planned to take the vehicle to the dealer to be repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 13,500. The VIN was unavailable.

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The design of the 1997 Toyota Corolla sedan has a questionable safety design in the fuel filler tube. Part # 77201 or 7720112500 appears to be make of simple tube steel. This part is not protected from road hazards, chemicals, or road spray that contain salt such as northern u. S. , or seaside ares. Since this gas tube is unprotected clamps 77216a & 77218a hold this corrosive causing accelerated rusting, and premature failure of the steel pipe. This causes a fuel leak that result in a large discharge of fuel while fueling, and a large discharge of fuel while driving . While driving, pressure pulls fuel from the mounted tank, to the lowest point behind the tank which is right where the above listed clamps to the body. This could see an estimated discharge of 25% of the tank 13g capacity or 3. 25g of fuel discharged per tank. Additionally, with the weakening of the fuel tube, at the outside edge of the uni-body frame. A driver side rear collision could shear off the fuel tube from the body-frame clamps, and igniting from the sparks generated by the cheap steel tube. Then fed directly from the back flush of fuel from the tank.

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The fuel pump assembly is mounted in the top of the fuel tank , hanging down submerged in the gas. One of the power wires from the pump assy. Going to the electrical connector at the top mounting plate of the pump, was badly burned and melted causing the pump not to work when it warmed up along with this electrical connector. Remember this is inside the fuel tank. This could have created a serious explosion ! Toyota issued a recall for "ecm" (electronic control module) problems associated with stalling engine, sudden loss of power and engine cranks and will not start. I think some of the "ecm " problems could have been mis-diagnosed and were this burnt wire and connector from the fuel pump. On top of that this repair cost me approx. $1500. 00 but maybe it saved my life. For safety reasons alone , this should be looked into and resolved. I hope this might help someone else before they are hurt.

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The contact owns a 2009 Toyota Corolla. She noticed that whenever she added fuel to the gas tank, the fuel gauge didn't register that it was full. The computer chip failed to register the correct amount of fuel that was in the vehicle. She took the vehicle to the dealer three times for the failure. The dealer stated that they did not locate a failure and she should avoid adding fuel to it's capacity. The dealer also stated that if they take apart the gas sending unit they are not sure it that would determine the failure; therefore, no parts were replaced. The failure mileage was 1,000 and the current mileage was 17,200.

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