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

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1. DISCHARGE FUEL SYSTEM PRESSURE Discharge fuel system pressure. Refer to «PRECAUTION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv) .
2. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) . Refer to «REMOVAL - Step 1»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
3. REMOVE REAR DECK FLOOR BOX . Refer to «REMOVAL - Step 2»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
4. REMOVE REAR NO. 3 FLOOR BOARD . Refer to «REMOVAL - Step 3»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
5. DISCONNECT CABLE FROM 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) .
6. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY HINT: Refer to «REMOVAL»(/toyota/prius-phv/pre-iii-2010-2011/remont/auxiliary-emission-control-systems/#emission-control-system-service-information-except-phv)
7. DISCONNECT ENGINE WIRE Disconnect the 4 fuel injector connectors. Disconnect the 4 connectors. Remove the bolt. Detach the 2 clamps to disconnect the wire harness.
8. DISCONNECT FUEL TUBE SUB-ASSEMBLY Release the claw and remove the No. 1 fuel pipe clamp. Pinch the tube connector, and then pull the tube connector off of the pipe. NOTE: Check for foreign matter in the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the connector and fuel pipe. Do not use any tools to separate the connector and pipe. Do not forcefully bend, kink or twist the hose. Keep the connector and pipe free from foreign matter. If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it. Put the connector in a plastic bag to prevent damage and contamination.
9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY Remove the bolt. Remove the 2 bolts and the fuel delivery pipe sub-assembly. NOTE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe.
10. REMOVE NO. 1 DELIVERY PIPE SPACER Remove the 2 delivery pipe spacers from the cylinder head.
11. REMOVE FUEL INJECTOR ASSEMBLY Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly. Remove the O-ring from each fuel injector. For reinstallation, attach a tag or label to each injector shaft. NOTE: Prevent entry of foreign objects by covering the fuel injectors with plastic bags. Remove the 4 injector vibration insulators.

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1. INSPECT FUEL INJECTOR ASSEMBLY Check the resistance. Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 11.6 to 12.4 ohms If the result is not as specified, replace the injector assembly. Check the operation. Inspect the injector injection volume. WARNING: Perform the inspection in a well-ventilated area. Do not perform the inspection near a naked flame. Connect SST (fuel tube connector) to SST (hose), then connect them to the fuel pipe (vehicle side). TEXT IN ILLUSTRATION *1 SST (Hose) *2 Fuel Pipe (Vehicle Side) *3 SST (Clip) *4 SST (Fuel Tube Connector) SST: 09268-31012 90467-13001 95336-08070 09268-41500 NOTE: Ensure that the SST connector O-rings are not damaged and are free of foreign objects as they are used to seal the connections between the fuel tube connector and pipe. Install a new O-ring onto the fuel injector assembly. TEXT IN ILLUSTRATION *1 SST (Hose) *2 SST (Clip) *3 SST (Adapter) *4 O-ring *5 SST (Clamp) *6 Vinyl Tube Connect SST (adapter and hose) to the injector assembly, and hold the injector assembly and union with SST (clamp). SST: 09268-31012 09268-41110 09268-41300 90467-13001 95336-08070 Set the injector assembly in a graduated cylinder. WARNING: Install a suitable vinyl tube onto the injector assembly to prevent gasoline from spraying. Operate the fuel pump. See step 1 . Connect SST (wire) to the injector assembly and the battery for 15 seconds, and measure the injection volume with the graduated cylinder. Test each injector 2 or 3 times. SST: 09842-30080 Standard Injection Volume Tester Connection Condition Specified Condition Positive terminal - Ground terminal Per 15 seconds 60 to 73 cc (3.7 to 4.5 cu.in.) Difference between each injector 13 cc (0.8 cu.in.) or less NOTE: Always do the switching on the battery side. If the injection volume is not as specified, replace the injector assembly. Inspect for leaks. In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leaks from the injector. Standard fuel drop 1 drop or less every 25 minutes If the injection volume is not as specified, replace the injector assembly.

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1. INSTALL FUEL INJECTOR ASSEMBLY Install a new insulator and O-ring to each fuel injector assembly. TEXT IN ILLUSTRATION *1 O-ring *2 Insulator Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly. While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe sub-assembly. NOTE: Do not damage the fuel injector assembly or O-ring. Do not twist the O-ring. After installing each fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one.
2. INSTALL NO. 1 DELIVERY PIPE SPACER Install the 2 No. 1 delivery pipe spacers onto the cylinder head. NOTE: Install the No. 1 delivery pipe spacers in the correct direction.
3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE: Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly. Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly. Install the bolt to secure the fuel delivery pipe sub-assembly. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
4. CONNECT FUEL TUBE SUB-ASSEMBLY Push the tube connector to the pipe until the tube connector makes a "click" sound. NOTE: Before connecting the connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe. After connecting the fuel tube connector and pipe, check that they are securely connected by trying to pull them apart. Engage the lock claw to install the No. 1 fuel pipe clamp.
5. CONNECT ENGINE WIRE Install the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 4 fuel injector connectors. Connect the 4 connectors. Attach the 2 clamps to connect the wire harness.
6. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY HINT: Refer to «INSTALLATION»(/toyota/prius-phv/pre-iii-2010-2011/remont/auxiliary-emission-control-systems/#emission-control-system-service-information-except-phv)
7. INSTALL REAR NO. 3 FLOOR BOARD . Refer to «INSTALLATION - Step 58»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
8. INSTALL REAR DECK FLOOR BOX . Refer to «INSTALLATION - Step 59»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
9. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) . Refer to «INSTALLATION - Step 60»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
10. CONNECT CABLE TO 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) .
11. INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv)

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1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Remove the fuel suction tube assembly with pump and gauge. Refer to «REMOVAL»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-service-information-except-phv) .
2. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2
3. REMOVE FUEL PUMP Disconnect the connector of the fuel pump harness. Disconnect the fuel pump filter hose. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank. TEXT IN ILLUSTRATION *1 Fuel Tube *2 Fuel Sub-tank NOTE: Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to «PRECAUTION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv) . Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump filter and fuel pump from the fuel filter. NOTE: Do not damage the fuel pump filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump. Disconnect the fuel pump harness connector. Remove the O-ring and spacer from the fuel pump. TEXT IN ILLUSTRATION *1 O-ring *2 Spacer NOTE: Be careful not to damage the sealing surface. HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration.
4. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY Using a screwdriver with its tip wrapped in protective tape, remove the fuel pressure regulator assembly. NOTE: Slowly pull out the fuel pressure regulator assembly because the O-ring is firmly installed between the regulator and the fuel filter. Remove the 2 O-rings from the pressure regulator assembly. TEXT IN ILLUSTRATION *1 O-ring

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1. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY Apply gasoline to 2 new O-rings and then install them to the fuel pressure regulator assembly. TEXT IN ILLUSTRATION *1 O-ring Install the fuel pressure regulator assembly.
2. INSTALL FUEL PUMP See step 1
3. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1
4. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Install the fuel suction tube assembly with pump and gauge. Refer to «INSTALLATION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-service-information-except-phv) .

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1. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to «REMOVAL - Step 1»(/toyota/prius-phv/pre-iii-2010-2011/remont/seats/#seat-service-information-except-phv)
2. REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear floor service hole cover. Disconnect the fuel pump connector.
3. DISCHARGE FUEL SYSTEM PRESSURE HINT: Refer to «PRECAUTION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv)
4. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) . Refer to «REMOVAL - Step 1»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
5. REMOVE REAR DECK FLOOR BOX . Refer to «REMOVAL - Step 2»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
6. REMOVE REAR NO. 3 FLOOR BOARD . Refer to «REMOVAL - Step 3»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
7. DISCONNECT CABLE FROM 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) .
8. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY Remove the tube joint clip and disengage the fuel tank main tube clamp, then pull the fuel tube joint out of the plug of the fuel suction tube assembly. TEXT IN ILLUSTRATION *1 Tube Joint Clip *2 Fuel Tank Main Tube Clamp *3 Fuel Tube Joint *4 O-ring NOTE: Check that there is no dirt or other foreign objects around the fuel tube joint before disconnecting it. Clean the joint if necessary. It is necessary to prevent mud or dirt from entering the joint. If mud or dirt gets in the joint, the O-rings may not seal properly. Only disconnect the joint by hand. Do not bend, kink or twist the nylon tubes. Protect the contact surfaces by covering it with a plastic bag.
9. REMOVE FUEL PUMP GAUGE RETAINER Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer. SST: 09808-14020 09808-01410 09808-01420 09808-01430 HINT: Engage the SST claws securely with the fuel pump gauge retainer holes to secure SST. Install SST while pressing the SST claws toward the fuel pump gauge retainer (towards the center of SST). Using SST, loosen the fuel pump gauge retainer. SST: 09808-14020 09808-01410 09808-01420 09808-01430 NOTE: Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result. Loosen the retainer by turning it counterclockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank. HINT: The holes on the fuel pump gauge retainer can be fitted into the tips of SST. Remove the fuel pump gauge retainer while holding the fuel suction tube assembly by hand.
10. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Remove the fuel suction tube assembly with pump and gauge from the fuel tank. NOTE: Make sure that the fuel sender gauge arm does not bend. Remove the gasket from the fuel tank.

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1. REMOVE FUEL SENDER GAUGE ASSEMBLY See step 2
2. REMOVE FUEL PUMP Disconnect the connector of the fuel pump harness. Disconnect the fuel pump filter hose. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel sub-tank. TEXT IN ILLUSTRATION *1 Fuel Tube *2 Fuel Sub-tank NOTE: Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. Refer to «PRECAUTION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv) . Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump filter and fuel pump from the fuel filter. NOTE: Do not damage the fuel pump filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump. Disconnect the fuel pump harness connector. Remove the O-ring and spacer from the fuel pump. TEXT IN ILLUSTRATION *1 O-ring *2 Spacer NOTE: Be careful not to damage the sealing surface. HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration.

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1. INSPECT FUEL PUMP Check the resistance. Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1 - 2 20°C (68°F) 0.2 to 3.0 ohms If the result is not as specified, replace the fuel pump. Check fuel pump operation. Apply battery voltage between terminals 1 and 2. Check that the pump operates. NOTE: These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always switch the voltage on and off on the battery side, not the fuel pump side. If the pump does not operate, replace the fuel pump. If the pump does not operate, replace the fuel pump.

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1. INSTALL FUEL PUMP Apply gasoline to a new O-ring. Then install the O-ring and spacer to the fuel pump. TEXT IN ILLUSTRATION *1 O-ring *2 Spacer Connect the fuel pump harness connector. Engage the 5 claws of the fuel pump. NOTE: Make sure that the O-ring is not cut or pinched during the installation. Engage the claws securely. Do not remove the fuel filter. Engage the 2 claws of the No. 1 fuel suction support. Engage the 2 claws of the fuel suction support and install the fuel filter and the fuel pump onto the fuel sub-tank. Align the groove of the fuel pump filter hose with the cutout of the fuel sub-tank and install the hose. NOTE: Do not apply excessive force to the fuel tube or the suction support. Connect the connector of the fuel pump harness.
2. INSTALL FUEL SENDER GAUGE ASSEMBLY See step 1

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1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Install a new gasket onto the fuel tank. Install the fuel suction tube assembly with pump and gauge to the fuel tank. TEXT IN ILLUSTRATION *1 Protrusion *2 Notch NOTE: Make sure that the fuel sender gauge arm does not bend. Align the protrusions of the fuel suction tube assembly with pump and gauge with the notchs of the fuel tank. NOTE: Ensure that the fuel suction tube gasket is in the correct position.
2. INSTALL FUEL PUMP GAUGE RETAINER While holding the fuel suction tube assembly with pump and gauge by hand, position the fuel pump gauge retainer and tighten it lightly by hand. TEXT IN ILLUSTRATION *1 Lock Point *2 Mark *3 Front of Vehicle NOTE: Check that the contact surface of the fuel tank retainer is not scratched or damaged, and prevent the entry of foreign objects. Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer. SST: 09808-14020 09808-01410 09808-01420 09808-01430 HINT: Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position. Engage the SST claws securely with the fuel pump gauge retainer holes to secure SST. Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST). Using SST, align the marks on the fuel tank and fuel pump gauge retainer. TEXT IN ILLUSTRATION *1 Lock Point *2 Starting Point *3 Front of Vehicle SST: 09808-14020 09808-01410 09808-01420 09808-01430 NOTE: Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result. Tighten the retainer by turning it clockwise while holding SST down.
3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip. TEXT IN ILLUSTRATION *1 Tube Joint Clip *2 Fuel Tank Main Tube clamp *3 Fuel Tube Joint *4 O-ring *5 Collars NOTE: Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tank main tube cannot be pushed out. Connect the fuel pump connector.
4. CONNECT CABLE TO 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) .
5. INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-inspection-except-phv)
6. INSTALL REAR FLOOR SERVICE HOLE COVER Install the rear floor service hole cover with new butyl tape.
7. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to «INSTALLATION - Step 9»(/toyota/prius-phv/pre-iii-2010-2011/remont/seats/#seat-service-information-except-phv)
8. INSTALL REAR NO. 3 FLOOR BOARD . Refer to «INSTALLATION - Step 58»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
9. INSTALL REAR DECK FLOOR BOX . Refer to «INSTALLATION - Step 59»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)
10. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) . Refer to «INSTALLATION - Step 60»(/toyota/prius-phv/pre-iii-2010-2011/remont/exteriorinterior-trim/#interior-panels-trim-service-information-except-phv)

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1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Remove the fuel suction tube assembly with pump and gauge. Refer to «REMOVAL»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-service-information-except-phv) .
2. DRAIN FUEL
3. REMOVE REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover) . Refer to «REMOVAL - Step 11»(/toyota/prius-phv/pre-iii-2010-2011/remont/suspension-rear/#rear-suspension-system-service-information-except-phv)
4. REMOVE REAR FLOOR SIDE MEMBER COVER RH (w/ Floor Under Cover) . Refer to «REMOVAL - Step 12»(/toyota/prius-phv/pre-iii-2010-2011/remont/suspension-rear/#rear-suspension-system-service-information-except-phv)
5. REMOVE REAR SUSPENSION BRACE SUB-ASSEMBLY . Refer to «REMOVAL - Step 13»(/toyota/prius-phv/pre-iii-2010-2011/remont/suspension-rear/#rear-suspension-system-service-information-except-phv)
6. REMOVE REAR FLOOR STEP UNDER COVER SUB-ASSEMBLY (w/ Floor Under Cover) . Refer to «REMOVAL - Step 5»(/toyota/prius-phv/pre-iii-2010-2011/remont/auxiliary-emission-control-systems/#emission-control-system-service-information-except-phv)
7. REMOVE NO. 1 FUEL TANK PROTECTOR Remove the 3 bolts and the No. 1 fuel tank protector.
8. DISCONNECT FUEL CUT-OFF TUBE Disconnect the fuel cut-off tube from the charcoal canister assembly. TEXT IN ILLUSTRATION *1 Retainer HINT: Do not remove the retainer. NOTE: Remove any dirt or foreign matter on the fuel cut-off tube connector before performing this work. Do not allow any scratches or foreign matter on the parts when disconnecting them as the fuel cut-off tube connector has an O-ring that seals the pipe. Perform this work by hand. Do not use any tools. Do not forcibly bend, twist or turn the fuel cut-off tube. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel cut-off tube. If the vent hose connector and pipe are stuck, push and pull to release them.
9. DISCONNECT FUEL TANK BREATHER TUBE Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration. TEXT IN ILLUSTRATION *1 Retainer *2 Quick Connector *3 Pipe *4 O-ring Pull out the fuel tank breather tube. NOTE: Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary. It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly. Do not use any tools in this operation. Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag. When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE Pull the tabs of the retainer to disengage the lock claws and pull it down as shown in the illustration TEXT IN ILLUSTRATION *1 Retainer Pull out the fuel tank to filler pipe hose. NOTE: Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary. It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly. Do not use any tools in this operation. Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag. When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY TEXT IN ILLUSTRATION *1 Retainer *2 Quick Connector *3 Pipe *4 O-ring Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration. Pull out and remove the fuel tank main tube sub-assembly. NOTE: Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary. It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly. Do not use any tools in this operation. Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag. When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
12. REMOVE FUEL TANK ASSEMBLY Remove the 2 bolts and disconnect the parking brake cable assembly. Support the fuel tank using an engine lifter. Remove the 4 set bolts of the 2 fuel tank bands. Lower the engine lifter to remove the fuel tank. NOTE: Slowly operate the engine lifter to lower the fuel tank. Do not drop the fuel tank. When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
13. REMOVE FUEL TANK CUSHION Remove the 3 No. 1 fuel tank cushions and 2 No. 2 fuel tank cushions. TEXT IN ILLUSTRATION *1 No. 1 Fuel Tank Cushion *2 No. 2 Fuel Tank Cushion

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1. INSTALL FUEL TANK CUSHION Install 3 new No. 1 fuel tank cushions and 2 new No. 2 fuel tank cushions as shown in the illustration. TEXT IN ILLUSTRATION *1 No. 1 Fuel Tank Cushion *2 No. 2 Fuel Tank Cushion
2. INSTALL FUEL TANK ASSEMBLY Support the fuel tank using an engine lifter. Raise the engine lifter, then install the fuel tank to the vehicle. NOTE: Do not drop the fuel tank. When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts. Tighten the 4 set bolts of the 2 fuel tank bands. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) NOTE: First temporarily install the bolts of the tank bracket. Then temporarily install the bolts of the tank bands. Finally, tighten all of the bolts. Connect the parking brake cable assembly with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY Push in the fuel tank main tube connector to the pipe and push up the retainer so that the claws engage. TEXT IN ILLUSTRATION *1 Retainer *2 Quick Connector *3 Pipe *4 O-ring NOTE: Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before starting this step. After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.
4. CONNECT FUEL TANK TO FILLER PIPE HOSE Push in the hose connector to the filler pipe and install the retainer. TEXT IN ILLUSTRATION *1 Retainer NOTE: Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces. After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
5. CONNECT FUEL TANK BREATHER TUBE Push in the fuel tank breather tube connector to the pipe and push up the retainer so that the claws engage. TEXT IN ILLUSTRATION *1 Retainer *2 Quick Connector *3 Pipe *4 O-ring NOTE: Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before starting this step. After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.
6. CONNECT FUEL CUT-OFF TUBE Push in the fuel cut-off tube connector to the charcoal canister and push up the retainer so that the claws engage. TEXT IN ILLUSTRATION *1 Retainer NOTE: Check that there are no scratches or foreign matter around the connected part of the fuel cut-off tube connector and pipe before performing this work. After connecting the fuel cut-off tube, check that the fuel cut-off tube is securely connected by pulling the fuel cut-off tube connector and the charcoal canister.
7. INSTALL NO. 1 FUEL TANK PROTECTOR Install the No. 1 fuel tank protector with the 3 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
8. INSTALL REAR FLOOR STEP UNDER COVER SUB-ASSEMBLY (w/ Floor Under Cover) . Refer to «INSTALLATION - Step 2»(/toyota/prius-phv/pre-iii-2010-2011/remont/auxiliary-emission-control-systems/#emission-control-system-service-information-except-phv)
9. INSTALL REAR SUSPENSION BRACE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 28»(/toyota/prius-phv/pre-iii-2010-2011/remont/suspension-rear/#rear-suspension-system-service-information-except-phv)
10. INSTALL REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover) . Refer to «INSTALLATION - Step 29»(/toyota/prius-phv/pre-iii-2010-2011/remont/suspension-rear/#rear-suspension-system-service-information-except-phv)
11. INSTALL REAR FLOOR SIDE MEMBER COVER RH (w/ Floor Under Cover) . Refer to «INSTALLATION - Step 30»(/toyota/prius-phv/pre-iii-2010-2011/remont/suspension-rear/#rear-suspension-system-service-information-except-phv)
12. ADD FUEL
13. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Install the fuel suction tube assembly with pump and gauge. Refer to «INSTALLATION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-service-information-except-phv) .

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Remove the fuel suction tube assembly with pump and gauge. Refer to «REMOVAL»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-service-information-except-phv) .
2. REMOVE FUEL SENDER GAUGE ASSEMBLY Disconnect the 3 harness clamps. NOTE: Do not damage the wire harness. Remove the 2 harness protectors from the wire harness. NOTE: Do not damage the wire harness. Disconnect the connector of the fuel sender gauge assembly. Release the lock as shown in the illustration and slide the fuel sender gauge assembly to remove it.

Scheme 89

1. INSPECT FUEL SENDER GAUGE ASSEMBLY Remove the fuel sender gauge assembly. Check that the float moves smoothly between F and E. Measure the resistance between terminals 1 and 2 of the connector according to the value(s) in the table below. Standard Resistance Float Level Resistance (ohms) F 12.0 to 18.0 Between E and F 12.0 to 415.0 (Gradually changes) E 405.0 to 415.0 If the value is not as specified, replace the fuel sender gauge assembly. TEXT IN ILLUSTRATION *1 Front view of wire harness connector: (to Fuel Sender Gauge Assembly) *2 Fuel Sender Gauge Assembly

Scheme 90

1. INSTALL FUEL SENDER GAUGE ASSEMBLY Install the fuel sender gauge assembly by sliding it downward. Connect the connector of the fuel sender gauge assembly. Install the 2 harness protectors. NOTE: Do not damage the wire harness. Connect the 3 harness clamps.
2. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Install the fuel suction tube assembly with pump and gauge. Refer to «INSTALLATION»(/toyota/prius-phv/pre-iii-2010-2011/remont/fuel-system/#engine-fuel-system-service-information-except-phv) .

See also:
• PRECAUTION
• REMOVAL - Step 1
• INITIALIZATION
• REMOVAL
• REMOVAL - Step 1
• REMOVAL - Step 11
• REMOVAL