Inspection Procedure

1. Operate the intelligent tester according to the steps on the display and select "ACTIVE TEST".

   METER: 

   METER
   
   

   Item	Test Details	Diagnostic Note
   FUEL GAUGE	OFF, EMPTY, 1/2, FULL	-

   OK: Needle indication is normal. 

NG : REPLACE COMBINATION METER ASSEMBLY 

OK : GO TO NEXT STEP 

1. Operate the intelligent tester according to the steps on the display and select "DATA LIST".

   METER: 

   DATA LIST
   
   

   Item	Measurement Item/Range (Display)	Normal Condition	Diagnostic Note
   FUEL GAUGE	Fuel input signal Min.: 0, Max.: 255	Fuel gauge indicates (F): 47 Fuel gauge indicates (1/2): 148 Fuel gauge indicates (E): 205	-

   OK: Fuel value signal displayed on the tester is almost the same as needle indication. 

OK : REPLACE COMBINATION METER ASSEMBLY 

NG : GO TO NEXT STEP. 

1. Disconnect the fuel tank wire.
2. Shorten the terminals 3 (FE) and 4 (FS) on wire harness side.
3. Disconnect the battery (-) terminal, then reconnect.
4. Turn the ignition switch to the ON position.

   Standard: Fuel receiver gauge indicates F or more. 

   Fig 1: Disconnecting Fuel Tank Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to step   6 

NG : GO TO NEXT STEP 

1. Disconnect the C9 connector and fuel tank wire.
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance 

   COMBINATION METER AND FUEL TANK WIRE
   
   

   Tester Connection	Condition	Specified Condition
   C9-2 (FE) - C9-19 (FUEL SENDER)	Always	Below 1 Ω
   C9-19 (FUEL SENDER) - Body ground	Always	10 kΩ or higher

   Fig 2: Checking Harness And Connector (Between Combination Meter And Fuel Tank Wire)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG : REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK : GO TO NEXT STEP 

NG : REPLACE HYBRID VEHICLE CONTROL ECU 

1. Disconnect the fuel tank wire from the fuel sender gauge assembly.
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance 

   FUEL TANK WIRE
   
   

   Tester Connection	Condition	Specified Condition
   2 (FS) - 4 (L2)	Always	Below 1 Ω
   3 (FE) - 3 (FE)	Always	Below 1 Ω
   4 (L2) - Body ground	Always	10 kΩ or higher

   Fig 3: Inspecting Fuel Tank Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG : REPLACE FUEL TANK WIRE 

OK : GO TO NEXT STEP 

1. Check the operation of the float moving smoothly between F and E.
2. Disconnect the fuel sender gauge connector.
3. Remove the fuel sender gauge assembly.
4. Measure the resistance between the terminals 2 (FE) and 3 (FS) of connector according to the value(s) in the table below.

   OK 

   FUEL SENDER GAUGE ASSEMBLY
   
   

   Float Level	Resistance (Ω)
   F	13.5 to 16.5
   E	405.5 to 414.5

   Fig 4: Inspecting Fuel Sender Gauge Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG : REPLACE FUEL SENDER GAUGE ASSEMBLY 

OK : END