Toyota Prius 2002-06

Sequential Multi-Port Fuel Injection System (SFI)

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Fuel Pump



Removal & Installation


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Fig. Fuel tank access below the rear seat cushion



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Fig. Exploded view of the fuel tank and related components-2004-06 Prius shown

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure from the fuel system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove instrument panel finish panel lower center.
  8.  
  9. Remove the front floor panel brace and front exhaust pipe assembly.

    Click image to see an enlarged view

    Fig. Removal of the rear seat cushion assembly-2004-06 Prius shown

  10.  
  11. Remove the rear seat cushion as follows:


    1. Detach the seat cushion's 2 front hooks from the vehicle body by choosing a hook to detach first. Place your hands near one of the hooks, then lift the seat cushion to detach the hook.
    2.  
    3. Repeat for the other hook.
    4.  
    5. Detach the seat cushion's rear hook.
    6.  
    7. Remove the seat cushion.
    8.  

  12.  
  13. Remove the butyl tape and rear floor service hole cover.
    CAUTION
    Remove dirt or foreign objects on the fuel line connectors before any disconnecting procedures. Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel connectors have O-rings that seal the pipes. Perform such work by hand. Do not use any tools. Do not forcibly bend, twist or turn the nylon tube. Protect the connecting part by covering it with a plastic bag after disconnecting the tube. If the connector and pipe are stuck, push and pull them to release them.

  14.  
  15. Disconnect the fuel pump connector.
  16.  
  17. Disconnect the wire-to-wire connector.
  18.  
  19. Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank to canister tube from the pipe.
  20.  
  21. Remove the checker of the fuel tube connector from the pipe.
  22.  
  23. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe.
  24.  
  25. Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the pipe side to disconnect the fuel tank vent hose from the canister filter.
  26.  
  27. Pinch the retainer and pull out the suction tube connector with the suction tube connector pushed to the pipe side to disconnect the fuel suction tube from the fuel tank to filler pipe.
  28.  
  29. Pinch the retainer and pull out the No. 1 canister tube connector with the No. 1 canister tube connector pushed to the pipe side to disconnect the No. 1 canister tube from the fuel tank to filler pipe.
  30.  
  31. Set a transmission jack to the fuel tank.
  32.  
  33. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
  34.  
  35. Remove the 4 bolts and No. 1 fuel tank band right and left.
  36.  
  37. Operate the transmission jack, and then disconnect the fuel tank inlet pipe.
  38.  
  39. Operate the transmission jack, and then remove the fuel tank.
  40.  
  41. Remove the 3 nuts and rear fuel tank bracket.
  42.  
  43. Disconnect the wire to wire connector from the rear fuel tank bracket.
  44.  
  45. Disconnect the No. 2 fuel tank main tube from the clamp.
  46.  
  47. Remove the checker of the main tube connector from the pipe.
  48.  
  49. Pinch the retainer of the main tube connector, then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe.
  50.  
  51. Disconnect the fuel suction tube from the 2 No. 1 fuel tube clamps.
  52.  
  53. Pinch the retainer and pull out the suction tube connector with the quick connector pushed to the pipe side to disconnect the fuel suction tube from the pipe.
  54.  
  55. Disconnect the fuel tank to canister tube from the clamp.
  56.  
  57. Disconnect the fuel tank to canister tube from the 2 No. 1 fuel tube clamps.
  58.  
  59. Remove the fuel tank to canister tube from the fuel tank.
  60.  
  61. Remove the trap canister with pump module by performing the following:


    1. Disconnect the VSV connector.
    2.  
    3. Remove the clamp from the fuel tank vent hose and canister hose.
    4.  
    5. Remove the fuel tank vent hose from the 2 fuel tube clamps.
    6.  
    7. Remove the 2 bolts and trap canister with pump module and disconnect the ground terminal of the fuel tank wire.
    8.  
    9. Remove the gasket from the fuel tank.
    10.  
    11. Remove the 2 clamps from the trap canister with pump module.
    12.  

  62.  

To install:

  1. Install the trap canister with pump module by performing the following:


    1. (a) Install a new gasket to the fuel tank.
    2.  
    3. Insert the trap canister with pump module to the fuel tank. Be careful that the gasket does not drop in the fuel tank.
    4.  
    5. Install the 2 clamps to the trap canister with pump module.
    6.  
    7. Install the trap canister with pump module and connect the ground terminal of the fuel tank wire with the 2 bolts. Tighten the 2 bolts to 53 inch lbs. (6 Nm).
    8.  
    9. Install the fuel tank vent hose to the 2 fuel tube clamps.
    10.  
    11. Install the clamp to the fuel tank vent hose and canister hose.
    12.  
    13. Connect the VSV connector.
    14.  

  2.  
  3. Install the fuel tank to canister tube to the canister's hose.
  4.  
  5. Connect the fuel tank to canister tube to the 2 No. 1 fuel tube clamps.
    CAUTION
    Check that there are no scratches or foreign objects around any connected part of the fuel line connectors and pipes before these procedures. After connecting any fuel line tubes, check that the tube is securely connected by pulling on the connector.

  6.  
  7. Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to install the fuel suction tube to the pipe.
  8.  
  9. Connect the fuel suction tube to the 2 No. 1 fuel tube clamps.
  10.  
  11. Align the main tube connector with the pipe, and then push in the main tube connector until the retainer makes a "click" sound to install the No. 2 fuel tank main tube to the pipe. Install the checker to the pipe.

    Click image to see an enlarged view

    Fig. No. 2 fuel main tube and checker assembly installation-2004-06 Prius shown

  12.  
  13. Connect the No. 2 fuel tank main tube to the clamp.
  14.  
  15. Connect the connector clamp to the rear fuel tank bracket.
  16.  
  17. Install the rear fuel tank bracket with the 3 nuts and tighten to 53 inch lbs. (6 Nm).
  18.  
  19. Set the fuel tank to a transmission jack.
  20.  
  21. Operate the transmission jack, and then install the fuel tank to the vehicle.
  22.  
  23. Operate the transmission jack, and then connect the fuel tank inlet pipe.
  24.  
  25. Install the No. 1 fuel tank band right and left with the 4 bolts. Torque the 4 bolts to 29 ft. lbs. (39 Nm).
  26.  
  27. Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe.
  28.  
  29. Align the No. 1 canister tube connector with the pipe, and then push in the No. 1 canister tube connector until the retainer makes a "click" sound to connect the No. 1 canister tube to the fuel tank to filler pipe.
  30.  
  31. Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to connect the fuel suction tube to the fuel tank to filler pipe.
  32.  
  33. Align the fuel tank vent hose connector with the pipe, and then push in the fuel tank vent hose connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the canister filter.
  34.  
  35. Align the fuel tube connector with the pipe, and then push in the fuel tube connector until the retainer makes a "click" sound to connect the No. 2 fuel tank main tube to the pipe. Install the checker to the pipe.
  36.  
  37. Align the fuel tank to canister tube connector with the pipe, and then push in the fuel tank to canister tube connector until the retainer makes a "click" sound to connect the fuel tank to canister tube to the pipe.
  38.  
  39. Install the front exhaust pipe
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Check for fuel and exhaust leaks.
  44.  
  45. Install the front floor panel brace.
  46.  
  47. install the instrument panel finish panel lower center.
  48.  
  49. Attach new butyl tape to the rear floor service hole cover.
  50.  
  51. Connect the wire-to-wire connector.
  52.  
  53. Connect the fuel pump connector.
  54.  
  55. Install the rear floor service hole cover while adjusting it to the 3 convex parts of the floor panel.
    WARNING
    Be careful that the rear floor service hole cover does not overlap the convex parts of the floor panel when installing.

  56.  
  57. Install the rear seat cushion by engaging the 3 seat hooks.
  58.  
  59. Perform initialization.
  60.  

Fuel Rail & Injectors



Removal & Installation


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Fig. Fuel injectors and cylinder head cover.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure from the fuel system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the windshield wipers and windshield wiper motor and link assembly, if necessary.
  8.  
  9. Remove the front outer cowl top panel, if necessary.
  10.  
  11. Remove the air cleaner assembly.
  12.  
  13. On 2004-06 Prius models, perform the following:


    1. Disconnect the brake fluid level switch connector.
    2.  
    3. Remove the 2 bolts.
    4.  
    5. Disconnect the claw fitting, then remove the brake master cylinder reservoir.
    6.  
    7. Remove the No. 2 fuel vapor feed hose from the hose clamp.
    8.  
    9. Remove the connector clamp.
    10.  
    11. Remove the wire harness clamp, the 3 bolts and reservoir bracket.
    12.  

  14.  
  15. Remove the cylinder head cover.
  16.  
  17. Remove the No. 1 fuel pipe clamp.
  18.  
  19. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe.
    CAUTION
    Be careful not to drop the injectors when removing the delivery pipe.

  20.  
  21. Disconnect the 4 injector connectors from injector.
  22.  
  23. Remove the 3 bolts and delivery pipe together with the 4 injectors and fuel pipe.
  24.  
  25. Remove the 2 spacers from the cylinder head.
  26.  
  27. Pull out the 4 injectors from the delivery pipe.
  28.  
  29. Remove the O-ring and grommet from each injector.
  30.  

To install:

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Fig. Installation of new O-ring to the injectors.



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Fig. Installation of the fuel injectors to the fuel delivery pipe.

  1. Install the grommet to each injector.
  2.  
  3. Apply a light coat of spindle oil or gasoline to new O-ring and install them to each injector.
  4.  
  5. Apply a light coat of spindle oil or gasoline to the surface of the fuel delivery pipe which contacts the O-ring of the fuel injector.
  6.  
  7. Apply a light coat of spindle oil or gasoline to the O-ring again, and install the fuel injector by turning it right and left while pushing it onto the fuel delivery pipe.
    NOTE
    Be careful that the O-ring is not cracked or jammed when installing it.

  8.  
  9. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring.
  10.  
  11. Install the 4 injectors.
  12.  
  13. Position the injector connector outward.
  14.  
  15. Install 4 new insulators to the cylinder head.
  16.  
  17. Install the 2 delivery pipe spacers to the cylinder head.
  18.  
  19. Place the delivery pipe and fuel pipe together with the 4 injectors in position on the cylinder head and then temporarily tighten the 3 bolts.
  20.  
  21. Check that the injectors rotate smoothly. If the fuel injectors do not rotate, replace the O-ring.
  22.  
  23. Tighten the 2 bolts holding the delivery pipe to the cylinder head and tighten to 14 ft. lbs. (19 Nm). Tighten the bolt holding the fuel pipe to the cylinder head to 80 inch lbs. (9 Nm).
  24.  
  25. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube to the fuel delivery pipe.
  26.  
  27. Install the No. 1 fuel pipe clamp.
  28.  
  29. Install the cylinder head cover.
  30.  
  31. On 2004-06 Prius models, perform the following:


    1. Install the reservoir bracket and tighten the 3 bolts to 75 inch lbs. (8.5 Nm)..
    2.  
    3. Install the wire harness clamp and the connector clamp.
    4.  
    5. Install the No. 2 fuel vapor feed hose to the hose clamp.
    6.  
    7. Connect the claw fitting.
    8.  
    9. Install the brake master cylinder reservoir and tighten the 2 mounting bolts to 75 inch lbs. (8.5 Nm).
    10.  
    11. Connect the brake fluid level switch connector.
    12.  

  32.  
  33. Install the air cleaner assembly.
  34.  
  35. Install the front outer cowl top panel, if necessary. Tighten the panel bolts to 57 inch lbs. (6.4 Nm), and the No. 2 engine room relay block bolts to 74 inch lbs. (8.4 Nm).
  36.  
  37. Install the windshield wiper motor and link assembly and windshield wipers, if necessary.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. With the ignition ON and the engine OFF check for leaks.
  42.  
  43. Perform initialization on 2004-06 models.
  44.  

Throttle Body



Removal & Installation


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Fig. Exploded view of throttle body and related parts (1 of 2)



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Fig. Exploded view of throttle body and related parts (2 of 2)

 
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