2012 Toyota Prius Plug-inFACTORY OEM SERVICE PROCEDURE

Fuel Pump: Reassembly: Reassembly

  1. INSTALL FUEL PUMP 
    1. Apply gasoline to a new O-ring. Then install the O-ring and fuel pump spacer to the fuel pump.
      Fig 1: Identifying O-Ring And Spacer
      GTY221242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-ring
      *2 Fuel Pump Spacer
    2. Connect the fuel pump harness connector.
      Fig 2: Identifying Fuel Pump Harness Connector
      GTY213082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 5 claws of the fuel pump.
      Fig 3: Identifying Fuel Filter, Fuel Pump Filter & Claws
      GTY268740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Fuel Filter
      *2 Suction Filter
      NOTE:
      • Make sure that the O-ring is not cut or pinched during the installation.
      • Engage the claws securely.
      • Do not remove the suction filter.
    4. Engage the 2 claws of the No. 1 fuel suction support.
    5. Engage the 2 claws of the fuel suction support and install the fuel filter and the fuel pump onto the fuel sub-tank.
    6. Align the groove of the suction filter hose with the cutout of the fuel sub-tank and install the hose.
      Fig 4: Identifying Fuel Pump Filter Hose Groove
      GTY223567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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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.

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