Fuel System [inspection] Toyota Prius V I

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1. PRECAUTIONS Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary 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 No. 1 seat assembly LH. Refer to «REMOVAL»(/toyota/prius-v/i-2011-2014/remont/seats/#seats-service-information) . Remove the rear No. 1 seat assembly RH. Refer to «REMOVAL»(/toyota/prius-v/i-2011-2014/remont/seats/#seats-service-information) . Remove the rear floor service hole cover. Refer to «REMOVAL - Step 12»(/toyota/prius-v/i-2011-2014/remont/fuel-system/#fuel-system-service-information) . Disconnect the fuel pump connector. Put the engine in inspection mode. Refer to «INSPECTION MODE PROCEDURE»(/toyota/prius-v/i-2011-2014/remont/hoistjack/#introduction) . Start the engine. After the engine has stopped on its own, turn the power 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-v/i-2011-2014/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-v/i-2011-2014/remont/hoistjack/#introduction__initialization) . Connect the fuel pump connector. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely. Install the rear floor service hole cover with new butyl tape. Refer to «INSTALLATION - Step 7»(/toyota/prius-v/i-2011-2014/remont/fuel-system/#fuel-system-service-information) . Install the rear No. 1 seat assembly LH. Refer to «INSTALLATION»(/toyota/prius-v/i-2011-2014/remont/seats/#seats-service-information) . Install the rear No. 1 seat assembly RH. Refer to «INSTALLATION»(/toyota/prius-v/i-2011-2014/remont/seats/#seats-service-information) .
3. FUEL LINE When disconnecting a high-pressure fuel line, a large amount of gasoline will spray out. 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. 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 matter on the pipe connections. Remove the No. 2 fuel pipe clamp. TEXT IN ILLUSTRATION *1 No. 2 Fuel Pipe Clamp *a Type A *b Type B NOTE: Do not reuse the fuel pipe clamp (Type B). Assemble SST to the connector as shown in the illustration. SST: 09268-21011 Turn SST, align the retainers inside the connector with the SST chamfers and insert SST into the connector. TEXT IN ILLUSTRATION *1 Retainer (4 places) *a Turn *b Push 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 matter 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 it is difficult to push the pipe into the connector, apply a small amount of clean engine oil to the tip of the pipe. TEXT IN ILLUSTRATION *a Push *b Pull After connecting, check that the pipe and the connector are securely connected by pulling on them. Install the No. 2 fuel pipe clamp. (Type A) TEXT IN ILLUSTRATION *1 No. 2 Fuel Pipe Clamp *a Type A *b Type B Install a new No. 2 fuel pipe clamp. (Type B) Inspect for fuel leaks. See step 1 . Perform the following procedure when disconnecting a fuel tube connector (quick type A): Release the claw and remove the No. 1 fuel pipe clamp. Disengage the lock claws by raising the fuel hose connector cover as shown in the illustration. TEXT IN ILLUSTRATION *1 Fuel Hose Connector Cover Check that there is no dirt or other foreign matter on the pipe and contact surface before disconnecting them. Clean them if necessary. Disconnect the connector from the pipe 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. TEXT IN ILLUSTRATION *1 Retainer *2 O-ring *a Pinch *b Pull Out Check that there is no dirt or other foreign matter on the contact surface of the disconnected pipe. Clean them away if necessary. Cover the disconnected pipe and connector with plastic bags to prevent damage and contamination. Perform the following procedure when connecting a fuel tube connector (quick type A): Check if there is any damage or foreign matter on the pipe connections. TEXT IN ILLUSTRATION *a Push *b Pull 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 it is difficult to push the pipe into the connector, apply a small amount of clean engine oil to the tip of the pipe. After connecting, check that the pipe and connector are securely connected by pulling on them. Engage the lock claws to the connector by pushing down on the fuel hose connector cover. TEXT IN ILLUSTRATION *1 Fuel Hose Connector Cover 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. Using a screwdriver with its tip wrapped with protective tape, pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank main tube. 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 plastic bags to prevent damage and contamination. Perform the following procedure when connecting a fuel tube connector (quick type B): Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and pipe. Align the quick connector with the pipe, connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer. If the connection is tight, apply a small amount of clean engine oil to the tip of the pipe. TEXT IN ILLUSTRATION *1 Retainer 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. Do not twist the connection part of the nylon tube and the quick connector when connecting them. Do not bend, kink, or twist the nylon tube. Do not remove the EPDM protector on the outside of the nylon tube. Do not close the piping by kinking the nylon tube.
4. INJECTOR Observe the following precautions when removing and installing a 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 onto the injector, do not damage the new 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 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 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 are no fuel leaks after performing maintenance anywhere on the fuel system. If there are fuel leaks, 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-v/i-2011-2014/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 Power 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-v/i-2011-2014/remont/hoistjack/#introduction__initialization) . Disconnect the fuel hose from the fuel main tube. Refer to «PRECAUTION»(/toyota/prius-v/i-2011-2014/remont/fuel-system/#fuel-system-inspection) . 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: 09268-31013 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 (-) auxiliary battery terminal. NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(/toyota/prius-v/i-2011-2014/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-v/i-2011-2014/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) 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 (-) 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-v/i-2011-2014/remont/hoistjack/#introduction__initialization) . 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
• REMOVAL - Step 12
• INSPECTION MODE PROCEDURE
• DTC CHECK / CLEAR
• INITIALIZATION
• PRECAUTION