TOYOTA PRIUS 2001 Service Repair Manual

B00417
SST
B11832
Fuel Pump
Connector
B00679
Vinyl Bag
SF±2
± SFISFI SYSTEM
1216 Author: Date:
2001 PRIUS (RM778U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (±) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Be careful during troubleshooting as there are numerous
transistor circuit, and even slight terminal contact can
cause further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care should be taken when pulling out and inserting wir-
ing connectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) Use SST for inspection or test of the injector or its wiring
connector.
SST 09842±30080
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures.
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Disconnect the fuel tube from the fuel tank.
(4) Drain the fuel remained inside the fuel tube.
(5) Prevent the disconnected fuel tube from damaging
and mixing foreign objects by covering them with a
vinyl bag.

B00061
New O±ring
CORRECT
WRONG Delivery Pipe
Injector
B00062
Delivery Pipe
SpacerO±ring
Grommet
B11839
Retainer
Pipe
Nylon Tube HousingO±Ring
B07690
SST
B11817
Retainer
(at 4 places)
± SFISFI SYSTEM
SF±3
1217 Author: Date:
2001 PRIUS (RM778U)
(b) Observe these precautions when removing and installing
the injector.
(1) Never reuse the O±ring.
(2) When placing a new O±ring on the injector, take
care not to damage it in any way.
(3) Coat a new O±ring with spindle oil or gasoline be-
fore installing never use engine, gear or brake oil.
(c) Install the injector to the delivery pipe and cylinder head,
as shown in the illustration. Before in installing the injec-
tor, must apply spindle oil or gasoline on the place where
a delivery pipe or a cylinder head touches on O±ring of the
injector.
(d) Observe these precautions when disconnecting the fuel
delivery pipe. The structure of the metallic connector is
shown as left.
(1) Remove the fuel pipe clamp.
(2) Get the metallic connector of the fuel tube assem-
bly, pull it out towards the rear and hold it as it is.
(3) Assemble SST to the connection as shown.
SST 09268±21010
(4) Turn SST, align the retainers inside the connector
with SST chamfered parts and incert SST into the
connector.

B11818
A13909
B11815
B00192
Vinyl Bag
S05382
Retainer
SF±4
± SFISFI SYSTEM
1218 Author: Date:
2001 PRIUS (RM778U)
(5) Hold SST as it at step 4, push the connector to-
wards SST to put the retainers on SST champfered
parts.
(6) Slide SST and the connector together towards the
fuel tube assembly.
(e) Observe these precautions when disconnecting the fuel
tube connector (quick type).
(1) Check if there is any dirt like mud on the pipe and
around the connector before disconnecting them
and clean the dirt away.
(2) Be sure to disconnect with hands.
(3) When the connector and the pipe are stuck, pinch
the retainer between the hands, push and pull the
connector to free to disconnect and pull it out. Do
not use any tool at this time.
(4) Inspect if there is any dirt or the likes on the seal sur-
face of the disconnected pipe and clean it away.
(5) Prevent the disconnected pipe and connector from
damaging and mixing foreign objects by covering
them with a vinyl bag.
(f) Observe these precautions when connecting the fuel
tube connector (quick type).
(1) Do not reuse the retainer removed from the pipe.
(2) Must use hands without using tools when to remove
the retainer from the pipe.
(3) Check if there is any damage or foreign objects on
the connected part of the pipe.

B11830
A13909
F12396
TOYOTA Hand±Held Tester
DLC3
± SFISFI SYSTEM
SF±5
1219 Author: Date:
2001 PRIUS (RM778U)
(4) Match the axis of the connector with axis of the pipe,
and push in the connector until retainer makes a
ºclickº sound. In case that the connections is tight,
apply little amount of new engine oil on the tip of the
pipe.
(5) After having finished the connection, check if the
pipe and the connector are securely connected by
pulling them.
(6) Check if there is any fuel leakage.
(g) Observer these precautions when handling nylon tube.
(1) Pay attention not to turn the connected part of the
nylon tube and the quick connector with force when
connecting them.
(2) Pay attention not to kink the nylon tube.
(3) Do not remove the nylon tube.
(4) Must not close the piping with the nylon tube by
bending it.
(h) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
(1) Connect the TOYOTA hand±held tester to the
DLC3.
(2) Turn the ignition switch ON and push TOYOTA
hand±held tester main switch ON.
(3) Select the active test mode on the TOYOTA hand±
held tester.
(4) Please refer to the TOYOTA hand±held tester oper-
ator 's manual for further details.
(5) If you have no TOYOTA hand±held tester, connect
the positive (+) and negative (±) leads from the bat-
tery to the fuel pump connector.
(See page SF±6)
(6) Check that there are no leaks from any part of the
fuel system.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand±held tester from the
DLC3.

F12396
TOYOTA Hand±Held Tester
DLC3
SF1KO±01
B11794
7
3
Battery
B11816
B09225
Fuel Tube Connector
SF±6
± SFIFUEL PUMP
1220 Author: Date:
2001 PRIUS (RM778U)
FUEL PUMP
ON±VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand±held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand±held
tester.
(d) Please refer to the TOYOTA hand±held tester operator's
manual for further details.
(e) If you have no TOYOTA hand±held tester, connect the
positive (+) lead from the battery to terminal 3 of the con-
necter, and the negative (±) lead to terminal 7.
(f) Check that there is pressure in the fuel inlet pipe from the
fuel line.
HINT:
If there is fuel pressure, you will hear the sound if fuel following.
If there is no pressure, check these parts, Fusible link, Fuses,
EFI Main relay, Fuel pump, ECM, and Witting connector.
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand±held tester from the
DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (±) terminal cable from the bat-
tery.
(c) Purchase the new fuel tube and take out the fuel tube
connector from its pipe.
Part No.: 23901±21020

B11815
B00194
SST
SST
(Hose)
Retainer
Fuel pipe
SST
(Hose)
SST
(Hose)
SST
Fuel Tube
Connection
B11794
7
3
Battery
± SFIFUEL PUMP
SF±7
1221 Author: Date:
2001 PRIUS (RM778U)
(d) Disconnect the fuel tube (fuel tube connector) from the
fuel pipe.
CAUTION:

Perform disconnecting operations of the fuel tube
connector (quick type) after observing the precau-
tions.

As there is retained pressure in the fuel pipe line, pre-
vent if from splashing inside the engine comport-
ment.
(e) Install SST (pressure gauge) as shown in the illustration
by using SST and fuel tube connector.
SST 09268±41047 (95336±08070), 09268±45014
(09268±41200, 09268±41220, 09268±41250)
(f) Wipe off any splattered gasoline.
(g) Reconnect the negative (±) terminal cable to the battery.
(h) Connect the TOYOTA hand±held tester to the DLC3.
If you have no TOYOTA hand±held tester, connect the positive
(+) lead from the battery to terminal 3 of the connecter, and the
negative (±) lead to terminal 7.
(i) Measure the fuel pressure.
Fuel pressure:
304 ± 343 kPa (3.1 ± 3.5 kgf/cm
2, 44 ± 50 psi)
If pressure is high, replace the fuel tank.
If pressure is low, check the Fuel hoses and connections, Fuel
pump.
(j) Disconnect the TOYOTA hand±held tester from the
DLC3.
(k) Start the engine.
(l) Measure the fuel pressure at idle.
Fuel pressure:
304 ± 343 kPa (3.1 ± 3.5 kgf/cm
2, 44 ± 50 psi)
(m) Stop the engine.
(n) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.

A13909
B11793
7
3Ohmmeter
B11794
7
3
Battery
SF±8
± SFIFUEL PUMP
1222 Author: Date:
2001 PRIUS (RM778U)
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump and/or injec-
tors.
(o) After checking fuel pressure, disconnect the negative (±)
terminal cable from the battery and carefully, remove the
SST and fuel tube connector to prevent gasoline from
splashing.
SST 09268±41047 (95336±08070), 09268±45014
(09268±41200, 09268±41220, 09268±41250)
(p) Reconnect the fuel tube (fuel tube connector).
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(q) Reconnect the negative (±) terminal cable to the battery.
(r) Check for fuel leakage.
3. REMOVE REAR SEAT CUSHION
4. REMOVE FLOOR SERVICE HOLE COVER
5. DISCONNECT FUEL PUMP & SENDER GAUGE CON-
NECTOR
6. INSPECT FUEL PUMP RESISTANCE
Using an ohmmeter, measure the resistance between terminals
3 and 7.
Resistance: 0.2 ± 3.0 W at 20°C (68 °F)
If the resistance is not as specified, replace the fuel tank.
7. INSPECT FUEL PUMP OPERATION
Connect the positive (+) lead from the battery to terminal 3 of
the connector and the negative (±) terminal 7. Check that the
pump operates.
NOTICE:

These tests must be done quickly (within 10 seconds)
to prevent the coil burning out.

Keep fuel pump as far away from the battery as pos-
sible.

Always do the switching at the battery side.
If operation is not as specified, replace the lead wire or fuel tank.
8. RECONNECT FUEL PUMP & SENDER GAUGE CON-
NECTOR
9. REINSTALL FLOOR SERVICE HOLE COVER
10. REINSTALL REAR SEAT CUSHION

B00066
Connector Fuel
Tube SST
SST (Hose)
(Union)
SST
(Clamp)
Fuel Pipe
(On vehicle) Injector
SF09K±11
S05359
Fuel Tube Connector
B00067
SST
Fuel PipeConnector(Hose)
Fuel Tube
B00068
SST (Hose)
SST (Union)
O±Ring
Vinyl Tube
SST(Clamp)
F12396
TOYOTA Hand±Held Tester
DLC3
SF±12
± SFIINJECTOR
2001 PRIUS (RM778U)
INSPECTION
1. INSPECT INJECTOR INSPECTION
CAUTION:
Keep injector clear of sparks during the test.
(a) Purchase the new fuel tube and take out the fuel tube
connector from its pipe.
Part No. 23901±22010
(b) Connect SST (hose) and fuel tube connector to the fuel
pipe.
SST 09268±41047
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(c) Install the grommet and O±ring to the injector.
(d) Connect SST (union and hose) to the injector, and hold
the injector to prevent gasoline from splashing out.
SST 09268±41047
(e) Put the injector into a graduated cylinder.
HINT:
Install a suitable vinyl tube onto the injector to prevent gasoline
from splashing out.
(f) Connect the TOYOTA hand±held tester to the DLC3.
(g) Turn the ignition switch ON and TOYOTA hand±held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(h) Select the active test mode on the TOYOTA hand±held
tester.
(i) Please refer to the TOYOTA hand±held tester operator's
manual for further details.

B00416
SST
(Wire)
Battery
B00069
± SFIINJECTOR
SF±13
2001 PRIUS (RM778U)
(j) If you have no TOYOTA hand±held tester, connect the
positive (+) and negative (±) leads from the battery to the
fuel pump connector (See page SF±9).
(k) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842±30080
Volume:
36 ± 46 cm
3 (2.1 ± 2.8 cu in.) per 15 sec.
Difference between each injector:
10 cm
3 (0.6 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST
(wire) from the battery and check the fuel leakage from
the injector.
SST 09842±30080
Fuel drop:
1 drop or less per 12 minutes
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative (±) terminal cable from the bat-
tery.
(d) Remove the SST and fuel tube connector.
SST 09268±41047
CAUTION:

Perform disconnecting operations of the fuel tube
connector (quick type) after observing the precau-
tions.

As there is retained pressure in the fuel pipe line, pre-
vent it from splashing inside the engine compart-
ment.
(e) Disconnect the TOYOTA hand±held tester from the
DLC3.

B00201
New Grommet
New O±Ring
SF1KQ±01
B00202
Turn
ConnectorPush
B11777
B11838
Rotate
Outward
B11777
SF±14
± SFIINJECTOR
2001 PRIUS (RM778U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPES
(a) Install the grommet to each injector.
(b) Apply a light coat of spindle oil or gasoline to new O±ring
and install them to each injector.
(c) Apply a light coat of spindle oil or gasoline on the place
where a delivery pipe touches on O±ring.
(d) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipes. Install the 4 injectors.
(e) Position the injector connector outward.
(f) Place the 2 spacers in position on the cylinder head.
(g) Place the delivery pipe and fuel pipe together with the 4
injectors in position on the cylinder head.
(h) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(i) Temporarily install the bolt holding the fuel pipe to the cyl-
inder head.
(j) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O±ring. Replace the O±ring.
(k) Position the injector connector connector outward.
(l) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 19 N´m (194 kgf´cm, 14 ft´lbf)
(m) Tighten the bolt holding the fuel pipe to the cylinder head.
Torque: 9.0 N´m (92 kgf´cm, 80 in.´lbf)