T-SB-0020-17_Rev

T-SB-0220-17
Rev2
May 23, 2017
Difficult to Refuel Vehicle
Service
Category
Engine/Hybrid System
Section
Fuel System
Market USA
Applicability
YEAR(S)
MODEL(S)
2019
Avalon HV
2018
Camry HV
2017 - 2018
Prius Prime
2016 - 2018
Prius
ADDITIONAL INFORMATION
REVISION NOTICE
May 31, 2019 Rev2:
 Applicability has been updated to include 2019 model year Avalon Hybrid vehicles.
 The entire bulletin has been updated.
June 1, 2018 Rev1:
 Applicability has been updated to include 2018 model year Camry Hybrid, Prius, and
Prius Prime vehicles.
 The entire bulletin has been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2016 – 2018 model year Prius, 2017 – 2018 model year Prius Prime, 2018 model year
Camry Hybrid, and 2019 model year Avalon Hybrid vehicles may exhibit an intermittent condition
where it is difficult to refuel. This condition may be caused by the fuel filler door not opening
completely, or interference between the fuel filler nozzle splash guard and the fuel door
lock switch.
If the fuel filler door does not open completely, or if interference occurs, the fuel vapor
containment valve may return to a closed position after pressing the fuel door opening button.
Follow the Repair Procedure in this bulletin to address this condition.
© 2019 Toyota Motor Sales, USA
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Production Change Information
 This bulletin applies to ALL 2019 model year Avalon hybrid vehicles.
 This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
LINE
PRODUCTION CHANGE EFFECTIVE VIN
1
JTDKBRFU#H3038680*
2
JTDKBRFU#H3552934*
Prius
Tsutsumi
Prius Prime
JTDKARFP#H3012455*
1
Camry HV
TMMK
4T1B21HK#JU007454**
2
4T1B21HK#JU507534**
*For fuel filler opening door hinge spring.
**For fuel filler opening door lock cover and retainer.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
EL9050
R & R Fuel Filler Opening Lid Hinge Spring
0.2
77366-52010
EL1805
R & R Fuel Filler Opening Door Lock Retainer
and Install Fuel Filler Opening Door Lock Cover
0.3
77377-78010
T1
T2
9A
14
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
Parts Information
MODEL
PART NUMBER
PART NAME
QTY
77378-07010
Cover, Fuel Filler Opening Lid Lock
1
N/A
77378-33010
Cover, Fuel Filler Opening Door Lock
1
77366-52010
77366-47020
Spring, Fuel Filler Opening Lid Hinge
1
N/A
77378-47030
Cover, Fuel Filler Opening Door Lock
1
77377-78010
77377-33040
Retainer, Fuel Filler Opening Door Lock
1
PREVIOUS
NEW
Avalon HV
N/A
Camry HV
Prius, Prius Prime
Avalon HV, Camry HV,
Prius, Prius Prime
© 2019 Toyota Motor Sales, USA
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Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Set*
00002-06001-01
1
*Essential SST
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Repair Procedure
1. Confirm the condition exists.
A. Does the vehicle exhibit an intermittent condition where it is difficult to refuel?
 YES — Continue to substep B.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
B. Is the vehicle a 2016 – 2017 model year Prius or 2017 model year Prius Prime?
 YES — Complete steps 2 – 13.

NO — Continue to substep C.
C. Is the vehicle a 2018 model year Camry HV, Prius, or Prius Prime or 2019 model year
Avalon HV?
 YES — Complete steps 7 – 13.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Press the fuel door open button.
Figure 1.
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Repair Procedure (continued)
3. Inspect the fuel filler door.
Does the fuel filler door open completely?
Refer to the following video links:
Fuel Filler Door Does NOT Open Completely
Fuel Filler Door Opens Completely

YES — Go to step 7.

NO — Continue to step 4.
4. Replace the fuel filler opening door hinge spring.
Figure 2.
A. Locate the spring.
1
c
1
B. Lightly pry up on the tab of the spring
with the plastic pry tool (SST) and push
the spring toward the inside of the
vehicle to remove it.
Fuel Filler Opening Door Hinge Spring
Figure 3.
© 2019 Toyota Motor Sales, USA
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Repair Procedure (continued)
C. Compare the original spring to the
NEW spring to ensure that the NEW
spring is installed.
Figure 4.
HINT
1
The NEW spring is larger than the
original spring.
2
1
Original Spring
2
New Spring
5. Install the NEW spring by pushing the spring into the fuel filler door until the tab is seated.
6. Confirm the repair.
Ensure the fuel filler door opens completely
when pressing the fuel door open button.
Figure 5.
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Repair Procedure (continued)
NOTE
The following steps (7 – 13) address the interference condition between the fuel filler nozzle splash guard
and the fuel door lock switch.
7. Press the fuel door open button.
8. Remove the fuel fill cap to gain access to
the fuel door lock switch retainer.
Figure 6.
NOTICE
Make sure no items drop into the fuel fill
opening, especially during fuel door lock
switch retainer replacement.
9. Remove the fuel door lock switch retainer by rotating it clockwise ¼ turn and pulling the
retainer toward the front of the vehicle.
Figure 7.
Figure 8. Retainer Removed
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Repair Procedure (continued)
10. Install the NEW fuel door lock
switch retainer.
Figure 9.
Line up the tabs of the NEW fuel door lock
switch retainer, slide it toward the rear of
the vehicle, and rotate counterclockwise
¼ turn until it locks into place.
11. Install the fuel door lock switch cover.
Line up the tabs on the retainer/cover and push the cover toward the rear of the vehicle until it
locks into place.
Figure 10. Camry HV and Avalon HV
Figure 11. Prius and Prius Prime
12. Install the fuel fill cap and close the fuel door.
13. Confirm the condition is no longer present.
© 2019 Toyota Motor Sales, USA