In July, 2003 (please refer to ODI id number: 10030262) our 1997 Toyota Camry ce (manual transmission) began leaking large amounts of gasoline. It was determined internal pressure had caused the tank to bulge out and rip at the seams. After two soldering attempts were made to patch the tank, the entire tank was replaced with a new one. A pressure test was conducted but no problems were found. In February 2005 the gas tank started leaking again. The same bulge from inside out was found as had previously been seen with the old and since replaced tank. The tank was removed & sent out for welding, returned and tests were conducted on the charcoal filter & vacuum switch. Both tested fine. The vacuum switch was replaced as the cost of replacing the charcoal filter was too expensive and since it didn't show failure, it didn't appear to be necessary. The mechanic suggested periodic tests in case the problem was intermittent. Also, the heat distributor (I believe that's the name for the metal between the exhaust pipe & the gas tank to keep the tank from overheating & exploding) was found to have been "wrinkled" but from the pressure of the in-out expansion of the tank, not from an out-in push that would have been caused from driving over something. Less than two weeks later, the gas leak returned. Toyota was contacted and we were referred to the local dealership customer service manager. The csm coordinated with the service department to have the car put up on the rack and looked at. Three individuals, including the csm declared it was an "external leak from the patch" and felt it was nothing they were willing to investigate further. They did suggest replacing the tank and doing further investigations to attempt to duplicate the process, however, the expenses are so extraordinary, we have opted to replace the tank with a used one and look at other replacement vehicle options, possibly selling parts or towing to a junk yard.

- Chico, CA, USA