2004 Toyota PriusFACTORY OEM SERVICE PROCEDURE

Fuel Injector ASSY: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See    DISCHARGE FUEL SYSTEM PRESSURE . 
  2. REMOVE REAR FLOOR BOARD NO. 2 (See  REAR FLOOR BOARD NO. 2 REMOVAL  ).
  3. REMOVE DECK FLOOR BOX REAR. (See  DECK FLOOR BOX REAR REMOVAL  ) 
  4. REMOVE REAR FLOOR BOARD NO. 3. (See  REAR FLOOR BOARD NO. 3 REMOVAL  ) 
  5. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL). (See  ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) REMOVAL  ) 
  6. REMOVE WINDSHIELD WIPER ARM COVER. See  Fig 1 
  7. REMOVE RIGHT FRONT WIPER. See  Fig 1  .
    8. Fig 1: Identifying Windshield Wiper & Cowl Panel Components
    G00953911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE LEFT FRONT WIPER ARM. See  Fig 1  .
  9. REMOVE HOOD TO COWL TOP SEAL. See  Fig 1  .
  10. REMOVE COWL TOP VENTILATOR LOUVER LH. See  Fig 1  .
  11. REMOVE COWL TOP VENTILATOR LOUVER RH. See  Fig 1  .
  12. REMOVE WINDSHIELD WIPER LINK ASSY. See  Fig 1  .
  13. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT 
    1. Remove the 2 bolts then remove the engine room relay block No. 2.
    2. Remove the 4 wire harness clamps. See Fig 2.
      Fig 2: Identifying 4 Wire Harness Clamps
      G00953914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 7 bolts, then remove the cowl top panel outer front. See Fig 3.
      Fig 3: Identifying 7 Bolts
      G00953915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE AIR CLEANER ASSY (See  Fig 4  .
    15. Fig 4: Identifying Air Cleaner Components
    G00953912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY 
    1. Disconnect the brake fluid level switch connector.
    2. Remove the 2 bolts.
    3. Separate the claw fitting, then remove the brake master cylinder reservoir. See Fig 5.
      Fig 5: Locating Claw Fitting
      G00953916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE RESERVOIR BRACKET 
    1. Remove the fuel vapor feed hose No. 2 from the hose clamp.
    2. Remove the connector clamp.
    3. Remove the wire harness clamp.
    4. Remove the 3 bolts, then remove the reservoir bracket. See Fig 6.
      Fig 6: Removing Reservoir Bracket
      G00953917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CYLINDER HEAD COVER SUB-ASSY 
    1. Remove the 2 wire harness clamps.
    2. Disconnect the 4 fuel injector connectors.
    3. Disconnect the 4 ignition coil connectors.
    4. Remove the 3 bolts, then remove the engine wire and brake master cylinder reservoir cover. See Fig 7.
      Fig 7: Identifying Wire Harness Clamps, Fuel Injector Connectors And Ignition Coil Connectors
      G00953918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts, then remove the 4 ignition coils. See Fig 8.

      HINT: 

      Each ignition coil is installed with 1 bolt.

      Fig 8: Identifying Ignition Coil Bolts
      G00953919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the ventilation hose from the ventilation valve. See Fig 9.
    7. Disconnect the ventilation hose No. 2 from the cylinder head cover.
      Fig 9: Disconnecting Ventilation Hoses
      G00953920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 9 bolts, 2 seal washers and 2 nuts, then remove the cylinder head cover. See Fig 10.
      Fig 10: Locating Cylinder Head Cover Bolts
      G00953921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL DELIVERY PIPE SUB-ASSY 
    1. Disconnect the fuel tube from the fuel delivery pipe.
      1. Remove the EFI fuel pipe clamp No. 1.
      2. Pinch the retainer of the fuel tube connector, then pull put the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe. See Fig 11
        Fig 11: Disconnecting The Fuel Tube From The Fuel Delivery Pipe
        G00953922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove dirt or foreign objects on the fuel tube connector before this work.
      • Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the connected part by covering it with a vinyl bag after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull them to release.
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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.