2004 Toyota PriusFACTORY OEM SERVICE PROCEDURE

Fuel System: Precaution

  1. PRECAUTION 
    1. Before working on the fuel system, disconnect the engine wire No. 2 (battery negative terminal).
    2. Do not work on the fuel system near fire. Never smoke during the work.
    3. Keep rubber or leather parts away from gasoline.
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    CAUTION:
    • Before removing the fuel system parts, take precautions to prevent gasoline spill.
    • As some pressure remains in the fuel line even after taking precautions to prevent gasoline spill, use a shop rag to prevent gasoline splash when disconnecting the fuel line.
    1. Set the vehicle to the "INSPECTION MODE". (See INSPECTION MODE ).
    2. Remove the rear floor board No. 2 (see REAR FLOOR BOARD REPLACEMENT ).
    3. Remove the deck floor box rear (see DECK FLOOR BOX REAR REPLACEMENT ).
    4. Remove the rear floor board No. 3 (see REAR FLOOR BOARD NO. 3 REPLACEMENT ).
    5. Disconnect the engine wire No. 3 (battery negative terminal) (see ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
    6. Remove the rear seat (see REAR SEAT REMOVAL ).
    7. Remove the rear floor service hole cover.
    8. Disconnect the fuel pump connector.
    9. Connect the engine wire No. 3 (battery negative terminal) (see ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
    10. Start the engine.
    11. After the engine stops (rough idle), turn the power switch OFF.
      Fig 1: Disconnecting Fuel Pump Connector
      G02920051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      DTC P0171 (system to lean) may be present.

    12. Crank the engine again, then check that the engine does not start.
    13. Remove the fuel tank cap, then discharge the pressure in the fuel tank completely.
    14. Disconnect the engine wire No. 3 (battery negative terminal) (see ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
    15. Connect the fuel pump connector.
    16. Install the rear floor service hole cover.
    17. Install the rear seat (see REAR SEAT INSTALLATION ).
    18. Connect the engine wire No. 3 (battery negative terminal) (see NO. 3 (BATTERY NEGATIVE TERMINAL) REPLACEMENT ).
    19. Install the rear floor board No. 3.
    20. Install the deck floor box rear.
    21. Install the rear floor board No. 2.
  3. FUEL SYSTEM 
    1. When disconnecting the high-pressure fuel line, a large amount of gasoline will splash. So take the following precautions.
      1. Discharge the fuel system pressure (see step   DISCHARGE FUEL SYSTEM PRESSURE).
      2. Disconnect the fuel pump tube (see step  REMOVE FUEL TANK ASSY ).
      3. Drain the pressure remaining in the fuel pump tube.
      4. Cover the disconnected fuel pump tube (fuel tube joint and fuel tube connector) with a vinyl bag to prevent damage and intrusion of foreign objects.
      Fig 2: Cover Disconnected Fuel Pump Tube With Vinyl Bag To Prevent Damage
      G02920052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Take the following precautions when removing and installing the fuel injector.
      1. Do not reuse the O-ring.
      2. Do not damage a new O-ring when installing it to the fuel injector.
      3. Before installing a new O-ring, apply spindle oil or gasoline.
      Fig 3: Precautions While Removing & Installing Fuel Injector
      G02920053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.