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Home >> Toyota >> 2007 >> Highlander Hybrid Limited, AWD >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Meter (Hybrid) >> Meter / Gauge System >> Fuel Receiver Gauge Malfunction >> Inspection Procedure

Inspection Procedure

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

      METER 

      ACTIVE TEST REFERENCE CHART

      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. 

  2. READ VALUE OF INTELLIGENT TESTER 
    1. Operate the intelligent tester according to the steps on the display and select "DATA LIST".

      METER 

      DATA LIST REFERENCE CHART

      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. 

    NG: REPLACE COMBINATION METER ASSEMBLY 

    OK: Go to next step. 

  3. INSPECT COMBINATION METER ASSEMBLY 
    1. Disconnect the fuel tank wire BN1 connector.
      2. Fig 1: Identifying Combination Meter Connector Terminal
      G05204543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Create a short circuit between terminals 3 (FE) and 4 (FS) on the wire harness side.
    3. Disconnect the battery negative (-) terminal, then reconnect it.
    4. Turn the ignition switch to the ON position.

      OK: Fuel receiver gauge indicates F or more. 

    OK: Go to step  6

    NG: Go to next step. 

  4. CHECK HARNESS AND CONNECTOR (BETWEEN COMBINATION METER AND FUEL TANK WIRE) 
    1. Disconnect the C12 connector and fuel tank wire BN1 connector.
      Fig 2: Identifying Combination Meter And Fuel Tank Wire Connector Terminal
      G05204544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      RESISTANCE REFERENCE CHART

      Tester Connection Condition Specified Condition
      C12-2 (FE) - BN1-3 (FE) Always Below 1 Ω
      BN1-3 (FE) - Body ground Always 10 kΩ or higher
      C12-19 (FUEL SENDER) - BN1-4 (FS) Always Below 1 Ω
      C12-19 (FUEL SENDER) - Body ground Always 10 kΩ or higher

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step. 

  5. REPLACE COMBINATION METER ASSEMBLY 

    NEXT: REPLACE HYBRID VEHICLE CONTROL ECU 

  6. INSPECT FUEL TANK WIRE 
    1. Disconnect the fuel tank wire BN1 connector, and F12 connector from the fuel sender gauge assembly.
      Fig 3: Identifying Fuel Tank Wire Connector Terminal
      G05204545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      RESISTANCE REFERENCE CHART

      Tester Connection Condition Specified Condition
      F12-3 (FS) - BN1-4 (FS) Always Below 1 Ω
      F12-2 (FE) - BN1-3 (FE) Always Below 1 Ω
      BN1-4 (FS) - Body ground Always 10 kΩ or higher

    NG: REPLACE FUEL TANK WIRE 

    OK: Go to next step. 

  7. INSPECT FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the fuel sender gauge assembly.
      Fig 4: Identifying Fuel Sender Gauge Connector Terminal
      G05204546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the float moves smoothly between F and E.
    3. Disconnect the fuel sender gauge connector.
    4. Measure the resistance between terminals 1 (FE) and 2 (FS) of the connector according to the value(s) in the table below.

      Standard Resistance 

      RESISTANCE REFERENCE CHART

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

    NG: REPLACE FUEL SENDER GAUGE ASSEMBLY 

    OK: END 

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