Engine Fuel System (inspection) (except Phv) Toyota Prius PHV pre-III

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1. PRECAUTIONS Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal. Do not smoke or work near fire when handling the fuel system. 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 piece of cloth to prevent fuel from spraying or coming out. Remove the rear seat cushion assembly. Refer to «REMOVAL - Step 1»(/toyota/prius-phv/pre-iii-2010-2011/remont/seats/#seat-service-information-except-phv) . Remove the rear floor service hole cover. Disconnect the fuel pump connector. Put the vehicle in the "inspection mode". Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-phv/pre-iii-2010-2011/remont/hoistjack/#introduction-except-phv) . Start the engine. After the engine has stopped on its own, turn the power switch off. HINT: DTCs P0171/25 may be detected. Crank the engine again and make sure that the engine does not start. Disconnect the cable from the negative (-) battery terminal. NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(/toyota/prius-phv/pre-iii-2010-2011/remont/hoistjack/#introduction-except-phv__initialization) . Connect the fuel pump connector. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
3. FUEL LINE When disconnecting a high-pressure fuel line, a large amount of gasoline will spray out. Perform the following procedure: Discharge fuel system pressure. Disconnect the fuel tube. Drain the fuel remaining inside the fuel pump tube into a container. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination. TEXT IN ILLUSTRATION *1 Plastic Bag Perform the following procedure when disconnecting a fuel delivery pipe (metallic type): TEXT IN ILLUSTRATION *1 Retainer *2 O-ring *3 Nylon Tube *4 Housing *5 Pipe HINT: The structure of a fuel tube connector is as shown in the illustration. Check if there is any damage or foreign objects on the pipe connections. Remove the No. 2 fuel pipe clamp. TEXT IN ILLUSTRATION *1 No. 2 Fuel Pipe Clamp NOTE: Do not reuse the fuel pipe clamp. Find the metallic connector of the fuel tube assembly. Assemble SST to the connector as shown in the illustration. SST: 09268-21010 Turn SST, align the retainers inside the connector with the SST chamfers and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly. Perform the following procedure when connecting a fuel tube connector (metallic type): Check if there is any damage or foreign objects on the pipe connections. Match the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe. After connecting, check if the pipe and the connector are securely connected by pulling on them. Install a new No. 2 fuel pipe clamp. TEXT IN ILLUSTRATION *1 No. 2 Fuel Pipe Clamp Check for fuel leaks. Perform the following procedure when disconnecting a fuel tube connector (quick type A): Release the claw and remove the No. 1 fuel pipe clamp. Check that there is no dirt or other foreign objects on the pipe and contact surface before disconnecting them. Clean them if necessary. Disconnect the connector from the pipe by hand. NOTE: Be sure to disconnect the connector by hand. If the connector and the pipe are stuck, push in and pull on the connector to release them. Pull the connector out of the pipe carefully. Check that there is no dirt or other foreign objects on the contact surface of the disconnected pipe. Clean them away if necessary. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination. TEXT IN ILLUSTRATION *1 Plastic Bag Perform the following procedure when connecting a fuel tube connector (quick type A): Check if there is any damage or foreign objects on the pipe connections. Line up the two parts of the pipes to be connected, and push them together until the connector makes a "click" sound. 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 pipes, check that the pipe and connector are securely connected by pulling on them. Inspect for fuel leaks See step 1 . Engage the lock claw and 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 Check that there is no damage or foreign matter on the part of the pipe that contacts the connector. Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe. HINT: Be sure to disconnect it by hand. If the connector and pipe are stuck, pinch the fuel pipe by hand and push or pull the connector to disconnect it. Check for foreign matter on the seal surface of the disconnected pipe. Clean it if necessary. Cover the disconnected pipe and connector with a plastic bag to prevent damage and contamination. TEXT IN ILLUSTRATION *1 Plastic Bag Perform the following procedure when connecting a fuel tube connector (quick type B): Line up the two parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. 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 pipes, check that the pipe and connector are securely connected by pulling on them. Inspect for fuel leaks See step 1 . Observe the following precautions when handling a nylon tube: WARNING: Do not twist the connector part of the nylon tube or the quick connector when connecting them. Do not bend or twist the nylon tube. Do not remove the EPDM protector on the outside of the nylon tube. Do not pinch or kink the nylon tubes to prevent fuel leakage.
4. INJECTOR Observe the following precautions when removing and installing a fuel injector: Do not reuse an O-ring and insulator. When placing a new O-ring onto the injector, do not damage the O-ring. Coat the new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid. Install the injector into the delivery pipe and cylinder head as shown in the illustration. Apply grease or gasoline to the contact surfaces of the injector before installing the injector. TEXT IN ILLUSTRATION *1 Delivery Pipe *2 O-ring 3 Insulator
5. FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube assembly with pump and gauge. Doing so will cause reassembly of the fuel suction tube assembly with pump and gauge to be impossible as the tube is welded to the plate. TEXT IN ILLUSTRATION *1 Tube
6. INSPECT FOR FUEL LEAK Check that there is no fuel leakage after performing maintenance anywhere on the fuel system 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 power switch on (IG). NOTE: Do not start the engine. Turn the Techstream on. 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 is no fuel leakage after performing maintenance anywhere on the fuel system. If there is a fuel leak, repair or replace parts as necessary. Turn the power switch off. Disconnect the Techstream from the DLC3.
2. CHECK FUEL PRESSURE Discharge fuel system pressure. Refer to «PRECAUTION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv) . Using a voltmeter, measure the battery voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition Positive terminal - Negative terminal Power switch off 11 to 14 V Disconnect the cable from the negative (-) battery terminal. Disconnect the fuel hose from the fuel main tube. Refer to «PRECAUTION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv) . Install SST (pressure gauge) using other SST as shown in the illustration. TEXT IN ILLUSTRATION *1 SST (Clip) *2 SST (T-joint) *3 SST (Pressure Gauge) *4 SST (Hose) *5 SST (Tube Connector) *6 Fuel Tube SST: 09268-31012 09268-41500 90467-13001 95336-08070 SST: 09268-45014 09268-41200 09268-41220 09268-41250 Clean up any spilled gasoline. Connect the cable to the negative (-) battery terminal. 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 vehicle in the "inspection mode". Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-phv/pre-iii-2010-2011/remont/hoistjack/#introduction-except-phv) . 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) 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 or fuel injector. After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST to prevent gasoline from spraying. Reconnect the fuel tube to the main fuel tube (fuel tube connector). Install the No. 1 fuel pipe clamp to the fuel tube connector. Inspect for fuel leaks (Step 1).

See also:
• REMOVAL - Step 1
• INSPECTION MODE PROCEDURE
• INITIALIZATION
• PRECAUTION