Fuel Gauge Malfunction: Procedure

1. Connect the Techstream to the DLC3.
   Fig 1: Identifying No. 1 And 8 Segment

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the ignition switch ON and turn the tester ON.
3. Enter the following menus: Body Electrical / Combination Meter / Active Test.

   Body Electrical / Combination Meter / Active Test:

   Tester Display	Test Part	Control Range	Diagnostic Note
   Fuel Meter Operation	Fuel gauge	EMPTY: Segment No. 1 flashes. 1/2: Segments No. 1 to 4 illuminates. FULL: Segments No. 1 to 8 illuminates.	-

   OK

   Fuel receiver gauge segments are illuminated in accordance with the tester instructions.

NG → See step   6 

OK: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the ignition switch ON and turn the tester ON
3. Select the item below from the Data List, and read the value displayed on the Techstream.

   Body Electrical / Combination Meter / Data List:

   Tester Display	Measurement Item/Range	Normal Condition	Diagnostic Note
   Fuel Input(A/D)	Fuel input signal / Min.: 0 Max.: 255	Fuel receiver gauge segments No. 1 to No. 8 illuminate: 14 to 34 No. 1 to (No. 6, No. 7) illuminate: 77 to 109 No. 1 to (No. 4, No. 5) illuminate: 135 to 172 No. 1 to No. 2 illuminate: 175 to 188 No. 1 flashes: 194 to 200	-

   OK

   Fuel input signal displayed on the tester is approximately the same as indication.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Disconnect the J5 fuel sender gauge assembly connector.
   Fig 2: Identifying Combination Meter Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the combination meter assembly with its connectors connected.
3. Measure the voltage.

   Standard voltage

   Tester Connection	Condition	Specified Condition
   D1-3 (L) - Body ground	Ignition switch ON	11 to 14V

4. Reconnect the fuel sender gauge assembly connector.
5. Reinstall the combination meter assembly.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Remove the fuel sender gauge assembly.
   Fig 3: Inspecting Fuel Sender Gauge Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the float position is between E and F.
3. Measure the resistance between terminals 2 and 1 of the fuel sender gauge connector.

   Standard resistance

   Float Level	Float Position (mm (in.))	Specified Condition
   F	146.2 (5.76) to 158.2 (6.23)	13.5 Ω to 16.5 Ω
   1/2	76.4 (3.01) to 88.4 (3.48)	195.3 Ω to 221.3 Ω
   E	0 (0)	405.5 Ω to 414.5 Ω

4. Reinstall the fuel sender gauge assembly.

NG → See step   7 

OK: Go to next step 

1. Disconnect the D1 combination meter assembly connector.
   Fig 4: Identifying Combination Meter And Fuel Sender Gauge Assembly Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the J5 fuel sender gauge assembly connector.
3. Measure the resistance.

   Standard resistance

   Tester Connection	Specified Condition
   D1-3 (L) - J5-2	Below 1Ω
   J5-3 - Body ground	Below 1Ω

4. Reconnect the combination meter assembly and fuel sender gauge assembly connectors.

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK → See step   6