Fuel System (inspection) Toyota Prius C I

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1. PRECAUTIONS Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal. NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent gasoline from spilling out. Keep gasoline away from rubber or leather parts.
2. DISCHARGE FUEL SYSTEM PRESSURE WARNING: Perform the following procedure to prevent fuel from spilling out before removing any fuel system parts. Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out. Remove the rear seat cushion assembly. HINT: for Separate Type Seatback. Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/seats/#seats-service-information) . for Bench Type Seatback. Refer to «REMOVAL»(/toyota/prius-c/i-2011-2015/remont/seats/#seats-service-information) . Remove the rear floor service hole cover. Disconnect the connector from the fuel suction tube with pump and gauge assembly. Put the engine in inspection mode. Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Start the engine. After the engine has stopped on its own, turn the ignition switch off. Crank the engine again and make sure that the engine does not start. HINT: Some DTCs may be stored. Clear the DTCs before proceeding to the next step. Refer to «DTC CHECK / CLEAR»(/toyota/prius-c/i-2011-2015/remont/testing-diagnostics/#engine-control-system-diagnostics-introduction__dtc-check-clear) . Disconnect the cable from the negative (-) auxiliary battery terminal. NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction__initialization) . Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. Connect the fuel pump connector. Install the rear floor service hole cover with new butyl tape. Install the rear seat cushion assembly. HINT: for Separate Type Seatback. Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/seats/#seats-service-information) . for Bench Type Seatback. Refer to «INSTALLATION»(/toyota/prius-c/i-2011-2015/remont/seats/#seats-service-information) .
3. FUEL SYSTEM When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so perform the following procedure: Discharge the fuel system pressure. Disconnect the fuel tank main tube sub-assembly. Drain the fuel remaining inside the fuel tank main tube sub-assembly into a container. Cover the disconnected pipe and connector with plastic bags to prevent damage and contamination. Put a container under the connecting parts. Perform the following procedure when disconnecting the fuel tube connector (quick type A): Remove the No. 1 fuel pipe clamp. Check whether there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it and remove the foreign matter as necessary. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the fuel tube from the fuel pipe. TEXT IN ILLUSTRATION *1 Retainer *2 Nylon Tube *3 Fuel Pipe *4 O-ring *5 Fuel Tube Connector Pinch Pull Out NOTE: Be sure to disconnect the fuel tube connector by hand. If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release it. Pull the fuel tube connector out of the fuel pipe carefully. TEXT IN ILLUSTRATION Pull Push NOTE: Be sure to disconnect the fuel tube connector by hand. Check that there is no dirt or other foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean the surfaces if necessary. Cover the disconnected fuel pipe and fuel tube connector with a plastic bag to prevent damage and contamination. NOTE: Do not damage the pipe or fuel tube connector, and prevent entry of foreign matter. Perform the following procedure when connecting a fuel tube connector (quick type A): Push Check if there is any damage or foreign matter on the connecting parts of the fuel pipes. Line up the 2 parts of the fuel pipes to be connected, and push them together until the fuel tube connector makes a "click" sound. HINT: If the fuel pipe is difficult to push into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it. After connecting the fuel pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them. TEXT IN ILLUSTRATION Pull Inspect for fuel leaks See step 1 . Install the No. 1 fuel pipe clamp. Perform the following procedure when disconnecting a fuel tube connector (quick type B): TEXT IN ILLUSTRATION *1 Retainer Pull Pull Out Check that there is no damage or foreign matter on the part of the pipe that contacts the connector. Pull the tabs of the retainer to disengage the lock claws and pull out the fuel tube connector from the fuel pipe. NOTE: Be sure to disconnect the fuel tube connector by hand. If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release it. Pull the fuel tube connector out of the fuel pipe carefully. TEXT IN ILLUSTRATION Pull Push NOTE: Be sure to disconnect the fuel tube connector by hand. Check that there is no dirt or other foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean the surfaces if necessary. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination. Perform the following procedure when connecting the fuel tube connector (quick type B): TEXT IN ILLUSTRATION *1 Retainer Push Push Check if there is any damage or foreign matter on the connecting parts of the fuel pipes. Line up the pipe and connector and push them together until a "click" sound is heard. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it. After connecting the fuel pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them. Inspect for fuel leaks See step 1 .
4. INJECTOR Install the injector to the delivery pipe and the cylinder head as shown in the illustration. TEXT IN ILLUSTRATION *1 Delivery pipe *2 O-ring *3 Injector Vibration Insulator NOTE: Before installing the injector, be sure to apply a light coat of gasoline or spindle oil where the delivery pipe contacts the injector O-ring. Observe the following precautions when removing and installing the fuel injector. TEXT IN ILLUSTRATION *1 O-ring *2 Delivery pipe *a CORRECT *b INCORRECT Do not reuse the O-ring and insulator. When placing a new O-ring on the injector, do not damage the O-ring. Coat a new O-ring with spindle oil or gasoline before installing it. NOTE: Do not use engine oil, gear oil or brake fluid.
5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is welded to the plate. TEXT IN ILLUSTRATION *1 Tube
6. INSPECT FOR FUEL LEAK Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs See step 1 .

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1. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK Check fuel pump operation. Connect the Techstream to the DLC3. Turn the ignition switch to ON (IG) and turn the Techstream on. NOTE: Do not start the engine. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors. Inspect for fuel leaks. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary. Turn the ignition switch off. Disconnect the Techstream from the DLC3.
2. CHECK FUEL PRESSURE Discharge the fuel system pressure. Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-inspection) . Using a voltmeter, measure the auxiliary battery voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition Positive terminal - Negative terminal Ignition switch off 11 to 14 V Disconnect the cable from the negative (-) auxiliary battery terminal. NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction__initialization) . Disconnect the fuel pipe from the fuel main tube. Refer to «PRECAUTION»(/toyota/prius-c/i-2011-2015/remont/fuel-system/#fuel-system-inspection) . Install SST (pressure gauge) using SST and a fuel tube connector as shown in the illustration. TEXT IN ILLUSTRATION *1 SST (Hose Band) *2 SST (T-joint) *3 SST (Gauge) *4 SST (Hose Joint) *5 SST (Hose) *6 SST (Fuel Tube Connector) *7 Fuel Tube Sub-assembly (Vehicle Side) *8 Fuel Pipe (Vehicle Side) SST: 09268-45101 09268-41250 09268-41260 09268-41280 09268-41500 09268-41700 95336-08070 Wipe up any spilled gasoline. Connect the cable to the negative (-) auxiliary battery terminal. NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction__initialization) . Connect the Techstream to the DLC3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed. Measure the fuel pressure. Standard fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) If the fuel pressure is greater than the standard value, replace the fuel pressure regulator. If the fuel pressure is less than the standard value, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. Disconnect the Techstream from the DLC3. Put the engine in inspection mode. Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction) . Start the engine. Measure the fuel pressure at idle. Standard fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) HINT: Standard idle speed. Refer to «ON-VEHICLE INSPECTION - Step 7»(/toyota/prius-c/i-2011-2015/remont/mechanical/#engine-mechanical-service-information) Stop the engine. Check that the fuel pressure remains as specified for 5 minutes after the engine stops. Standard fuel pressure 147 kPa (1.5 kgf/cm 2 , 21 psi) or more If the fuel pressure is not as specified, check the fuel pump, pressure regulator and/or fuel injectors. After checking the fuel pressure, disconnect the cable from the negative (-) auxiliary battery terminal and carefully remove SST to prevent gasoline from spraying. NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(/toyota/prius-c/i-2011-2015/remont/hoistjack/#introduction__initialization) . Reconnect the fuel pipe to the fuel main tube (fuel tube connector). Install the No. 1 fuel pipe clamp to the fuel tube connector. Check for fuel leaks (Step 1). Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

See also:
• PRECAUTION
• REMOVAL
• DTC CHECK / CLEAR
• INITIALIZATION
• ON-VEHICLE INSPECTION - Step 7
• PRECAUTION