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Fuel Gauge Malfunction: Procedure

  1. PERFORM ACTIVE TEST USING TECHSTREAM (FUEL METER OPERATION) 
    1. Connect the Techstream to the DLC3.
    2. Turn the engine switch on (IG).
    3. Turn the tester ON.
    4. Enter following menus: Body Electrical / Combination Meter / Active Test.
    5. Check the operation by referring to the table below.
      COMBINATION METER:

      Tester Display Test Part Control Range Diagnostic Note
      Fuel Meter Operation Fuel receiver gauge EMPTY, 1/2, FULL -

      OK

      Needle indication is normal.

    NG → REPLACE COMBINATION METER 

    OK: Go to next step 

  2. READ VALUE USING TECHSTREAM (FUEL INPUT) 
    1. Connect the Techstream to the DLC3.
    2. Turn the engine switch on (IG).
    3. Turn the tester ON.
    4. Enter following menus: Body Electrical / Combination Meter / Data List.
    5. Check the values by referring to the table below.
      COMBINATION METER:

      Tester Display Measurement Item/Range Normal Condition Diagnostic Note
      Fuel Input Fuel input signal Min.: 0, Max.: 255 Fuel gauge indicates (F): 14
      Fuel gauge indicates (3/4): 36
      Fuel gauge indicates (1/2): 71
      Fuel gauge indicates (1/4): 107
      Fuel gauge indicates (E): 128      		 -

      OK

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

    NG → REPLACE COMBINATION METER 

    OK: Go to next step 

  3. INSPECT FUEL SENDER GAUGE ASSEMBLY (MAIN) 
    1. Disconnect the U9 fuel sender gauge connector.
    2. Measure the voltage of the wire harness side connector.
      Fig 1: Identifying U9 Fuel Sender Gauge Connector
      GTY102370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      STANDARD VOLTAGE:

      Tester Connection Condition Specified Condition
      U9-2 - U9-3 Engine switch on (ACC) or on (IG) 10 to 14 V
    3. Remove the fuel sender gauge assembly.
    4. Connect the fuel sender gauge connector.
    5. Check that the float position is between E and F.
      Fig 2: Checking Float Position Between EMPTY And FULL
      GTY102035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Measure the resistance between the terminals 2 and 3 of connector of the connector.
      STANDARD RESISTANCE:

      Float level Float Position mm (in.) Specified Condition
      F 51.4 (2.02) to 57.4 (2.26) 6.5 to 8.5 Ω
      E 121.7 (4.79) to 127.7 (5.03) 237.6 to 242.6 Ω

    NG → REPLACE FUEL SENDER GAUGE ASSEMBLY 

    OK: Go to next step 

  4. INSPECT FUEL SENDER GAUGE ASSEMBLY (SUB) 
    1. Disconnect the V11 fuel sender gauge connector.
    2. Measure the voltage of the wire harness side connector.
      Fig 3: Identifying V11 Fuel Sender Gauge Connector
      GTY108196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage

      Tester Connection Condition Specified Condition
      V11-2 - V11-3 Engine switch on (ACC) or on (IG) 10 to 14 V
    3. Remove the fuel sender gauge assembly.
    4. Connect the fuel sender gauge connector.
    5. Check that the float position is between E and F.
      Fig 4: Checking Float Position Between EMPTY And FULL
      GTY108198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Measure the resistance between the terminals 2 and 3 of connector of the connector.

      Standard resistance

      Float level Float Position mm (in.) Specified Condition
      F 69.9 (2.75) to 75.9 (2.99) 6.5 to 8.5 Ω
      E 103.1 (4.06) to 109.1 (4.30) 167.9 to 171.9 Ω

    NG → REPLACE FUEL SENDER GAUGE ASSEMBLY 

    OK: Go to next step 

  5. CHECK HARNESS AND CONNECTOR (BETWEEN COMBINATION METER AND FUEL SENDER GAUGE (MAIN)) 
    1. Disconnect the U9 fuel sender gauge connector.
      Fig 5: Identifying U9 Fuel Sender Gauge Connector And K31 Meter Connector
      GTY108225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the K31 meter connector.
    3. Measure the resistance of the wire harness side connector.

      Standard resistance

      Tester Connection Condition Specified Condition
      K31-19 - U9-2 Always Below 1 Ω
      U9-2 - Body ground Always 10 kΩ or higher

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (BETWEEN FUEL SENDER GAUGE (SUB) AND FUEL SENDER GAUGE (MAIN)) 
    1. Disconnect the U9 fuel sender gauge connector.
      Fig 6: Identifying U9 And V11 Fuel Sender Gauge Connector
      GTY108197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the V11 fuel sender gauge connector.
    3. Measure the resistance of the wire harness side connectors.

      Standard resistance

      Tester Connection Condition Specified Condition
      U9-3 - V11-3 Always Below 1 Ω
      V11-3 - Body ground Always 10 kΩ or higher

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  7. CHECK HARNESS AND CONNECTOR (BETWEEN COMBINATION METER AND FUEL SENDER GAUGE (SUB)) 
    1. Disconnect the V11 fuel sender gauge connectors.
      Fig 7: Identifying V11 Fuel Sender Gauge Connectors And K31 Meter Connectors
      GTY108226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the K31 meter connectors.
    3. Measure the resistance of the wire harness side connectors.

      Standard resistance

      Tester Connection Condition Specified Condition
      V11-2 - K31-34 Always Below 1 Ω
      K31-34 - Body ground Always 10 kΩ or higher

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK → REPLACE COMBINATION METER 

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