Tank Assembly problems of the 2006 Toyota Prius

Four problems related to tank assembly have been reported for the 2006 Toyota Prius. The most recently reported issues are listed below.

1 Tank Assembly problem

Failure Date: 02/09/2010

2006 Prius gasoline tanks has erratic behavior, based on temperature. Fill up capacity ranges from 6 to 10 gallons, on a 10. 9 gallons tank.

2 Tank Assembly problem

Failure Date: 01/01/2009

Passenger side hid headlight goes out every 3-4 months. At first it is intermittent, and difficult to say when failure occurs. Over time the period for failure gets shorter. Dealer says it is my problem. Cost of continual repair is over $300. Per light. Also, fuel gauge say add fuel when tank partially empty.

3 Tank Assembly problem

Failure Date: 10/15/2007

Hard time getting gas in the vehicle. For example, I was told by the dealership to let the gas gauge get down to 1/4 tank or less and fill the tank slowly as there may be air behind the bladder that is in the gas tank on the Prius. About 2 miles from the gas tank the "add fuel" warning came on in the vehicle. Upon pulling into the gas station and adding gas into the vehicle I was only able to get slightly over 4 gallons into the tank. The Prius had an 11. 9 gallon gas tank. So if the gas was really below 1/4 tank, why am I only getting 4 gallons in the tank. Even if the 1/4 tank means there are 3 gallons left in the tank, those 3 plus the 4 that I got in the tank still only add up to 7 gallons. What happened to the other 4+ gallons that I should have been able to put in the tank? this happens every time I put gas in the vehicle. So far the dealership has told me its because its cold outside that this happens. . . Well how do they explain it in summer? it was over 60 degrees when I got gas last Thursday. The have told me that I have to put the gas in slowly, and they have re-set the gas gauge.

4 Tank Assembly problem

Failure Date: 05/29/2006

Gas tank gauge says its completely full no matter how much fuel is in the tank. As of this writing I have driven approx. 120 miles on this tank of gas and the gauge still shows the tank as full. It has not yet been fixed.


Other Gasoline Fuel System related problems of the 2006 Toyota Prius

Gasoline Fuel System problems
4
Tank Assembly problems
4
Fuel Pump problems
1


Safety Ratings of Prius Cars
Fuel Economy of Prius Vehicles
Prius Service Bulletins
Prius Safety Recalls
Prius Defect Investigations