2012 Toyota Prius ThreeFACTORY OEM SERVICE PROCEDURE

Fuel System: Precaution: Precaution

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTIONS 
    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal.
      NOTE:

      After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work. Refer to PRECAUTION .

    2. Do not smoke or work near fire when handling the fuel system.
    3. 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.
    1. Remove the rear seat cushion assembly. Refer to REMOVAL - Step 4 .
    2. Remove the rear floor service hole cover.
      Fig 1: Identifying Rear Floor Service Hole Cover
      GTY217927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel pump connector.
      Fig 2: Identifying Connector
      GTY336472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Put the engine in inspection mode. Refer to INSPECTION MODE PROCEDURE .
    5. Start the engine.
    6. After the engine has stopped on its own, turn the power switch off.
    7. 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 .

    8. 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 .

    9. Connect the fuel pump connector.
    10. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
    11. Install the rear floor service hole cover with new butyl tape.
    12. Install the rear seat cushion assembly. Refer to INSTALLATION - Step 7 .
  3. FUEL LINE 
    1. When disconnecting a high-pressure fuel line, a large amount of gasoline will spray out. Perform the following procedure:
      1. Discharge the fuel system pressure.
      2. Disconnect the fuel tank main tube sub-assembly.
      3. Drain the fuel remaining inside the fuel tank main tube sub-assembly into a container.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Perform the following procedure when disconnecting a fuel delivery pipe (metallic type):
      Fig 3: Identifying Fuel Delivery Pipe Components (Metallic Type)
      GTY236721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-ring
      *3 Nylon Tube
      *4 Fuel Tube Connector
      *5 Fuel Pipe

      HINT: 

      The structure of a fuel tube connector is as shown in the illustration.

      1. Check if there is any damage or foreign matter on the fuel pipe connections.
      2. Remove the No. 2 fuel pipe clamp.
        Fig 4: Removing The No. 2 Fuel Pipe Clamp
        GTY266137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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).

      3. Assemble SST to the fuel tube connector as shown in the illustration.
        Fig 5: Assembling SST To Connection
        GTY217223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09268-21011 
      4. Turn SST, align the retainers inside the fuel tube connector with the SST chamfers and insert SST into the fuel tube connector.
        Fig 6: Aligning The Retainers Inside The Connector With The SST Chamfers And Insert SST Into The Connector
        GTY286334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer (4 places)
        *a Turn
        *b Push
      5. Slide SST and the fuel tube connector together towards the fuel tube assembly.
    3. Perform the following procedure when connecting a fuel tube connector (metallic type):
      1. Check if there is any damage or foreign matter on the fuel pipe connections.
      2. Match the axis of the fuel tube connector with the axis of the fuel pipe, and push the fuel pipe into the fuel tube connector until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe.
        Fig 7: Checking Damage Or Foreign Objects On The Pipe Connections
        GTY254655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Push
        *b Pull
      3. After connecting, check that the fuel pipe and the fuel tube connector are securely connected by pulling on them.
      4. Install the No. 2 fuel pipe clamp. (Type A)
        Fig 8: Installing A New No. 2 Fuel Pipe Clamp
        GTY284307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B
      5. Install a new No. 2 fuel pipe clamp. (Type B)
      6. Inspect for fuel leaks See step  1.
    4. Perform the following procedure when disconnecting a fuel tube connector (quick type A):
      1. Release the claw and remove the No. 1 fuel pipe clamp.
        Fig 9: Identifying Fuel Pipe Clamp And Lock Claw
        GTY216239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the lock claws by raising the fuel hose connector cover as shown in the illustration.
        Fig 10: Disengaging Lock Claws
        GTY339124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Hose Connector Cover
      3. Check that there is no dirt or other foreign matter on the fuel pipe and contact surface before disconnecting them. Clean them if necessary.
      4. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
        Fig 11: Push In And Pull On The Connector
        GTY257772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Retainer
        *2 O-ring
        *a Pinch
        *b Pull Out
      5. If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release them. Pull the fuel tube connector out of the fuel pipe carefully.
        NOTE:

        Be sure to disconnect it by hand.

      6. Check that there is no dirt or other foreign matter on the contact surface of the disconnected fuel pipe. Clean it if necessary.
      7. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    5. Perform the following procedure when connecting a fuel tube connector (quick type A):
      1. Check if there is any damage or foreign matter on the fuel pipe connecting parts.
        Fig 12: Checking That Fuel Pipe Is Secure
        GTY258855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Push
        *b Pull
      2. Match the axis of the fuel tube connector with the axis of the fuel pipe, and push the fuel pipe into the fuel tube connector until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe.
      3. After connecting, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
      4. Engage the lock claws to the fuel tube connector by pushing down on the fuel hose connector cover.
        Fig 13: Engaging Lock Claws
        GTY339123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Fuel Hose Connector Cover
      5. Inspect for fuel leaks See step  1.
      6. Engage the lock claw and install the No. 1 fuel pipe clamp.
        Fig 14: Identifying Fuel Pipe Clamp And Lock Claw
        GTY216239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Perform the following procedure when disconnecting a fuel tube connector (quick type B):
      Fig 15: Identifying Fuel Tube Connector (Quick Type B)
      GTY226851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      1. Check that there is no damage or foreign matter on the part of the fuel pipe that contacts the fuel tube connector.
      2. Detach the 2 claws of the fuel tube connector retainer. Push down on the fuel tube connector and disconnect it from the fuel pipe.
      3. If the fuel tube connector and fuel pipe are stuck, pinch the fuel pipe by hand and push or pull the fuel tube connector to disconnect it.
        Fig 16: Disconnecting Connector
        GTY104528Courtesy 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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