Quote Originally Posted by Mile2 View Post
Just been to casa to claim warranty for my fuel tank with huge mysterious dent just beneath the front strap.

Culprit of the Innova gas tank warp/leak was the filler cap, they disassembled the filler cap with me watching and viola!!! the air breather was clogged with soot like dirt that forms like a solid charcoal. They clean the filler cap's breather filter and vacuum buildup inside the tank was gone.

Evidently, Toyota knows this problem but no recall was done for the "FAULTY FILLER CAP DESIGN!!!". Newer Innova 2009 now has new design filler cap with larger breather holes and much more breather holes than its predecessor.

So if, you have older versions of Innova, Fortuner or Hilux be very cautious that one day your fuel filler cap's breather will get clogged and this will damage your fuel tank. While I was at the dealer's service area I notice another gas tank on the working table and when I look at it has the same large dent spot and same leak point (just beneath the front gas tank strap which is the weakest point).

Negative pressure builds up and thereby sucking the gas tank floor inward, and when the negative pressure is gone or when the car's engine is off for some time the gas tank floor will push back to its orginal form. The constant flippping inward and flipping outward of the gas tank will eventually crack open the corner bend just beneath the position of the front gas tank strap.
ref:
Pg 34 (2005-06 Innova manual)

Filler cap? Is this the same as the fuel tank cap?

What needs to be changed inorder to prevent the problem (dents and leaks)?

Hope you can provide pics. Thanks!