Toyota Corolla Cross: Fuel Receiver Gauge Malfunction

DESCRIPTION

FUEL RECEIVER GAUGE OPERATION

(a) OPERATION

The combination meter assembly uses the fuel sender gauge assembly to detect the amount of fuel remaining in the fuel tank assembly. The Hall IC built into the fuel sender gauge assembly changes the output voltage according to the amount of fuel remaining. The combination meter assembly receives fuel consumption signals from the ECM and detects the voltage output from the fuel sender gauge assembly and operates the fuel receiver gauge.

FUEL RECEIVER GAUGE READING

(a) During normal driving:

While driving, the fuel level indicated by the fuel receiver gauge decreases according to the fuel consumed. As the fuel level in the fuel tank may be unstable depending on the driving conditions, the combination meter assembly corrects the fuel receiver gauge reading based on the fluctuations in the fuel level.

(b) During refueling:

When fuel is added to the fuel tank, if the fuel level increases by a certain amount or more, the output of the fuel sender gauge assembly will change. The combination meter assembly detects this change and determines that refueling has been performed and calculates the volume of fuel added. This is called refueling judgment. The combination meter assembly adjusts the fuel receiver gauge reading based on the refueling judgment.

NOTICE:

Add fuel with the ignition switch off to ensure safety and to enable refueling judgment so that an appropriate fuel receiver gauge reading will be obtained.

REFUELING JUDGMENT CONDITIONS

(a) Normal judgment condition (When normal refueling method is used)

With the ignition switch off, the fuel sender gauge assembly detects a change of 5.0 liters (5.3 US qts, 4.4 Imp. qts) or more in the fuel level.

(b) Other judgment conditions (When other refueling method is used)

With the ignition switch ON, the vehicle and engine stopped, the fuel sender gauge assembly detects a change of 5.0 liters (5.3 US qts, 4.4 Imp. qts) or more in the fuel level.

PRECAUTION FOR REFUELING

(a) The fuel sender gauge assembly cannot detect changes in the fuel level within certain ranges (around points E and F). Therefore, even if the refueling judgment conditions are satisfied, the fuel receiver gauge reading may not change when the fuel level is within either range.

(b) When refueling judgment is performed, it takes up to approximately 25 seconds for the fuel receiver gauge reading to change to the appropriate level.

FORCED RESET OF FUEL RECEIVER GAUGE

When refueling judgment conditions are not met, if the output of the fuel sender gauge assembly and the fuel receiver gauge reading differ by 15.0 liters (15.9 US qts, 13.2 Imp. qts) or more for approximately 5 minutes continuously, the fuel receiver gauge reading will reflect the detected fuel level without correction and it may take up to approximately 25 seconds for the reading to change to the appropriate level.

CAUTION / NOTICE / HINT

NOTICE:

• When replacing the combination meter assembly, always replace it with a new one. If a combination meter assembly which was installed to another vehicle is used, the information stored in it will not match the information from the vehicle and a DTC may be stored.
• Before preforming this procedure, check for Meter / Gauge System DTC B150013 or B150113 which is stored if an open or short in the circuit is detected. If DTC B150013 or B150113 is output, perform troubleshooting and repairs as necessary.
• After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

  Click here

• When replacing the combination meter assembly, update the ECU security key.

  Click here

HINT:

• for 2WD with Gasoline Model:

  The fuel level warning light will come on when the fuel level is below 4.7 liters (5.0 US qts, 4.1 Imp. qts).

• for AWD with Gasoline Model:

  The fuel level warning light will come on when the fuel level is below 5.63 liters (5.9 US qts, 5.0 Imp. qts).

• for HEV Model:

  The fuel level warning light will come on when the fuel level is below 4.39 liters (4.6 US qts, 3.9 Imp. qts).

PROCEDURE

1.	CHECK FOR DTC (SFI SYSTEM)

(a) Check if SFI system DTCs are output.

Powertrain > Engine > Trouble Codes

Result	Proceed to
DTCs are not output	A
DTCs are output	B

B

GO TO SFI SYSTEM for M20A-FXS: Click here for M20A-FKS: Click here

A

2.	CHECK FOR DTC (ELECTRONICALLY CONTROLLED BRAKE SYSTEM)

(a) Check if electronically controlled brake system DTCs are output. (for HEV Model)

Chassis > Brake Booster > Trouble Codes Chassis > Brake/EPB > Trouble Codes

(b) Check if electronically controlled brake system DTCs are output. (for Gasoline Model)

Chassis > Brake/EPB > Trouble Codes

Result	Proceed to
DTCs are not output	A
DTCs are output	B

B

GO TO ELECTRONICALLY CONTROLLED BRAKE SYSTEM for HEV Model: Click here for Gasoline Model: Click here

A

3.	CHECK FOR DTC (METER / GAUGE SYSTEM)

(a) Check if DTC B150013 or B150113 is output.

Body Electrical > Combination Meter > Trouble Codes

Result	Proceed to
B150013 or B150113 is not output	A
B150013 or B150113 is output	B

B

GO TO B150013 OR B150113

A

4.	CHECK SYMPTOMS

(a) Ask the customer about the problem symptoms.

Result	Proceed to
Malfunction occurs when adding fuel (Even when refueled, display value does not increase)	A
Malfunction occurs when adding fuel (When refueled, display value increase is slow)	B
Malfunction occurs during normal driving (The reading does not change, decreases quickly or decreases when the vehicle is not being driven, etc.) (The problem symptom recurs)	C
Malfunction occurs during normal driving (The reading does not change, decreases quickly or decreases when the vehicle is not being driven, etc.) (The problem symptom does not recur)	D

B

GO TO STEP 6

C

GO TO STEP 8

D

GO TO STEP 10

A

5.	MANUALLY UPDATE FUEL RECEIVER GAUGE

(a) Perform a manual update of the fuel receiver gauge.

Click here

(b) Check that the display value of the fuel receiver gauge has changed.

OK

END HINT: Symptom caused by amount of fuel filled being too low to trigger refueling judgment, or refueling in an undetectable range.

NG

GO TO STEP 6

6.	PERFORM ACTIVE TEST USING GTS

(a) Perform the Active Test according to the display on the GTS.

Body Electrical > Combination Meter > Active Test

Tester Display	Measurement Item	Control Range	Diagnostic Note
Fuel Gauge Operation (Sender E)	Fuel receiver gauge (Fuel sender gauge lower limit)	ON	See [Display 1]
Fuel Gauge Operation (Empty)	Fuel receiver gauge (Fuel receiver gauge indicates E)	ON	See [Display 1]
Fuel Gauge Operation (Warning)	Fuel receiver gauge (Position at which fuel level warning light turns on/off)	ON	See [Display 1]
Fuel Gauge Operation (1/4)	Fuel receiver gauge (Fuel receiver gauge indicates 1/4)	ON	See [Display 1]
Fuel Gauge Operation (1/2)	Fuel receiver gauge (Fuel receiver gauge indicates 1/2)	ON	See [Display 1]
Fuel Gauge Operation (3/4)	Fuel receiver gauge (Fuel receiver gauge indicates 3/4)	ON	See [Display 1]
Fuel Gauge Operation (Full)	Fuel receiver gauge (Fuel receiver gauge indicates F)	ON	See [Display 1]
Fuel Gauge Operation (Sender F)	Fuel receiver gauge (Fuel sender gauge upper limit)	ON	See [Display 1]

HINT:

[Display 1]: Fuel Gauge Operation

• Refer to the following table for the specified fuel receiver gauge position for each selected value: for 4.2 Inch Type Multi-information Display

  Tester Display	Fuel Receiver Gauge Indication
  Fuel Gauge Operation (Sender E)	Approximately 1 is indicated
  Fuel Gauge Operation (Empty)	Approximately 2 is indicated
  Fuel Gauge Operation (Warning)	Approximately 3 is indicated
  Fuel Gauge Operation (1/4)	Approximately 4 is indicated
  Fuel Gauge Operation (1/2)	Approximately 5 is indicated
  Fuel Gauge Operation (3/4)	Approximately 6 is indicated
  Fuel Gauge Operation (Full)	Approximately 7 is indicated
  Fuel Gauge Operation (Sender F)	Approximately 8 is indicated

  

  *A	for 4.2 Inch Type Multi-information Display

  

  *A	for 7 Inch Type Multi-information Display

  for 7 Inch Type Multi-information Display

  Tester Display	Fuel Receiver Gauge Indication
  Fuel Gauge Operation (Sender E)	Segments illuminate 0/8
  Fuel Gauge Operation (Empty)	Segments illuminate 1/8
  Fuel Gauge Operation (Warning)	Segments illuminate 1/8
  Fuel Gauge Operation (1/4)	Segments illuminate 2/8
  Fuel Gauge Operation (1/2)	Segments illuminate 4/8
  Fuel Gauge Operation (3/4)	Segments illuminate 6/8
  Fuel Gauge Operation (Full)	Segments illuminate 8/8
  Fuel Gauge Operation (Sender F)	Segments illuminate 8/8

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Sender E)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Empty)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Warning)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (1/4)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (1/2)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (3/4)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Full)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Sender F)

Result	Proceed to
OK	A
NG	B

B

REPLACE COMBINATION METER ASSEMBLY

A

7.	CHECK FUEL RECEIVER GAUGE (OPERATION BY ADDING FUEL)

NOTICE:

As it is necessary to add more than a certain amount of fuel to the fuel tank, if the fuel level is near full, perform the following procedure then proceed to step (a). If the fuel tank is not near full, proceed to step (a) without performing the following procedure.

1. Turn the ignition switch off.
2. Remove 15 liters (15.9 US qts, 13.2 Imp. qts) or more of fuel from the fuel tank.
3. Turn the ignition switch to ON.
4. Wait 6 minutes or more.
5. Confirm that the fuel receiver gauge indicates a value in accordance with the removed amount of fuel.

(a) Record the fuel receiver gauge reading.

(b) Turn the ignition switch off.

(c) Disconnect the cable from the negative (-) auxiliary battery terminal.

HINT:

This resets the current fuel level information stored by the combination meter assembly.

(d) Wait 2 minutes or more.

(e) Connect the cable to the negative (-) auxiliary battery terminal.

(f) Wait 15 seconds or more. (w/ Canister Pump Module)

HINT:

If the cable is disconnected from the negative (-) auxiliary battery terminal, the pressure inside the fuel tank will change. After the cable is reconnected to the negative (-) auxiliary battery terminal, it takes approximately 15 seconds for the pressure inside the fuel tank to be restored. During this time, the indicated value of the fuel receiver gauge may change.

(g) Turn the ignition switch to ON.

(h) Drive the vehicle at 2 km/h (1 mph) or more, and then stop the vehicle on a flat surface.

(i) Turn the ignition switch off.

(j) Wait 30 seconds or more.

(k) Add the following amount of fuel or more.

• 5.0 liters (5.3 US qts, 4.4 Imp. qts)

(l) Turn the ignition switch to ON.

(m) Check that the fuel receiver gauge reading increases in proportion to the amount of fuel added.

NOTICE:

After turning the ignition switch to ON, it may take approximately 30 seconds until the fuel receiver gauge indicates the determined value.

Result	Proceed to
Fuel receiver gauge reading increases in proportion to the amount of fuel added	A
Fuel receiver gauge reading does not change even when fuel is added	B

A

GO TO STEP 10

B

REPLACE COMBINATION METER ASSEMBLY

8.	PERFORM ACTIVE TEST USING GTS

(a) Perform the Active Test according to the display on the GTS.

Body Electrical > Combination Meter > Active Test

Tester Display	Measurement Item	Control Range	Diagnostic Note
Fuel Gauge Operation (Sender E)	Fuel receiver gauge (Fuel sender gauge lower limit)	ON	See [Display 1]
Fuel Gauge Operation (Empty)	Fuel receiver gauge (Fuel receiver gauge indicates E)	ON	See [Display 1]
Fuel Gauge Operation (Warning)	Fuel receiver gauge (Position at which fuel level warning light turns on/off)	ON	See [Display 1]
Fuel Gauge Operation (1/4)	Fuel receiver gauge (Fuel receiver gauge indicates 1/4)	ON	See [Display 1]
Fuel Gauge Operation (1/2)	Fuel receiver gauge (Fuel receiver gauge indicates 1/2)	ON	See [Display 1]
Fuel Gauge Operation (3/4)	Fuel receiver gauge (Fuel receiver gauge indicates 3/4)	ON	See [Display 1]
Fuel Gauge Operation (Full)	Fuel receiver gauge (Fuel receiver gauge indicates F)	ON	See [Display 1]
Fuel Gauge Operation (Sender F)	Fuel receiver gauge (Fuel sender gauge upper limit)	ON	See [Display 1]

HINT:

[Display 1]: Fuel Gauge Operation

• Refer to the following table for the specified fuel receiver gauge position for each selected value: for 4.2 Inch Type Multi-information Display

  Tester Display	Fuel Receiver Gauge Indication
  Fuel Gauge Operation (Sender E)	Approximately 1 is indicated
  Fuel Gauge Operation (Empty)	Approximately 2 is indicated
  Fuel Gauge Operation (Warning)	Approximately 3 is indicated
  Fuel Gauge Operation (1/4)	Approximately 4 is indicated
  Fuel Gauge Operation (1/2)	Approximately 5 is indicated
  Fuel Gauge Operation (3/4)	Approximately 6 is indicated
  Fuel Gauge Operation (Full)	Approximately 7 is indicated
  Fuel Gauge Operation (Sender F)	Approximately 8 is indicated

  

  *A	for 4.2 Inch Type Multi-information Display

  

  *A	for 7 Inch Type Multi-information Display

  for 7 Inch Type Multi-information Display

  Tester Display	Fuel Receiver Gauge Indication
  Fuel Gauge Operation (Sender E)	Segments illuminate 0/8
  Fuel Gauge Operation (Empty)	Segments illuminate 1/8
  Fuel Gauge Operation (Warning)	Segments illuminate 1/8
  Fuel Gauge Operation (1/4)	Segments illuminate 2/8
  Fuel Gauge Operation (1/2)	Segments illuminate 4/8
  Fuel Gauge Operation (3/4)	Segments illuminate 6/8
  Fuel Gauge Operation (Full)	Segments illuminate 8/8
  Fuel Gauge Operation (Sender F)	Segments illuminate 8/8

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Sender E)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Empty)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Warning)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (1/4)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (1/2)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (3/4)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Full)

Body Electrical > Combination Meter > Active Test

Tester Display
Fuel Gauge Operation (Sender F)

Result	Proceed to
OK	A
NG	B

B

REPLACE COMBINATION METER ASSEMBLY

A

9.	CHECK FUEL RECEIVER GAUGE

(a) Record the fuel receiver gauge reading.

(b) Turn the ignition switch off.

(c) Disconnect the cable from the negative (-) auxiliary battery terminal.

HINT:

This resets the current fuel level information stored by the combination meter assembly.

(d) Wait 2 minutes or more.

(e) Connect the cable to the negative (-) auxiliary battery terminal.

(f) Wait 30 seconds or more.

(g) Turn the ignition switch to ON.

(h) Check if the fuel receiver gauge reading corresponds with the amount of fuel remaining in the fuel tank.

NOTICE:

After turning the ignition switch to ON, it may take approximately 30 seconds until the fuel receiver gauge indicates the determined value.

Result	Proceed to
Fuel receiver gauge reading corresponds with the amount of fuel remaining in the fuel tank	A
Fuel receiver gauge reading does not correspond with the amount of fuel remaining in the fuel tank	B

A

GO TO STEP 10

B

REPLACE COMBINATION METER ASSEMBLY

10.	CHECK VEHICLE TYPE

(a) Check vehicle condition.

Result	Proceed to
for 2WD with Gasoline Model	A
for AWD with Gasoline Model	B
for HEV Model	C

B

GO TO STEP 12

C

GO TO STEP 13

A

11.	INSPECT FUEL TANK ASSEMBLY

HINT:

Inspect the fuel tank assembly and fuel sender assembly for deformation, foreign matter or an improperly installed fuel receiver gauge, as this may be the cause of the fuel receiver gauge malfunction.

(a) Visually check the fuel tank assembly for any abnormalities.

(b) Check if there is an excessive amount of foreign matter in the fuel tank assembly.

(c) Visually check the fuel sender gauge assembly for damage and confirm that it operates correctly.

(d) Check the installation condition of the fuel tank assembly and fuel sender gauge assembly.

Result	Proceed to
Normal	A
Appearance of the fuel tank assembly is abnormal	B
There is an excessive amount of foreign matter in the fuel tank assembly	C
The fuel sender gauge assembly is visually damaged or does not operate correctly	D
The fuel tank assembly or fuel sender gauge assembly is not installed correctly	E

A

REPLACE COMBINATION METER ASSEMBLY

B

REPLACE FUEL TANK ASSEMBLY

C

CLEAN INSIDE OF FUEL TANK ASSEMBLY

D

REPLACE FUEL SENDER GAUGE ASSEMBLY

E

INSTALL FUEL TANK ASSEMBLY OR FUEL SENDER GAUGE ASSEMBLY CORRECTLY

12.	INSPECT FUEL TANK ASSEMBLY

HINT:

Inspect the fuel tank assembly and fuel sender assembly for deformation, foreign matter or an improperly installed fuel receiver gauge, as this may be the cause of the fuel receiver gauge malfunction.

(a) Visually check the fuel tank sub-assembly for any abnormalities.

(b) Check if there is an excessive amount of foreign matter in the fuel tank sub-assembly.

(c) Visually check the fuel sender gauge assembly and No. 2 fuel sender gauge assembly for damage and confirm that it operates correctly.

(d) Check the installation condition of the fuel tank assembly fuel sender gauge assembly and No. 2 fuel sender gauge assembly.

Result	Proceed to
Normal	A
Appearance of the fuel tank sub-assembly is abnormal	B
There is an excessive amount of foreign matter in the fuel tank sub-assembly	C
The fuel sender gauge assembly is visually damaged or does not operate correctly	D
The No. 2 fuel sender gauge assembly is visually damaged or does not operate correctly	E
The fuel tank sub-assembly or fuel sender gauge assembly is not installed correctly	F

A

REPLACE COMBINATION METER ASSEMBLY

B

REPLACE FUEL TANK ASSEMBLY

C

CLEAN INSIDE OF FUEL TANK ASSEMBLY

D

REPLACE FUEL SENDER GAUGE ASSEMBLY

E

REPLACE NO. 2 FUEL SENDER GAUGE ASSEMBLY

F

INSTALL FUEL TANK ASSEMBLY OR FUEL SENDER GAUGE ASSEMBLY CORRECTLY

13.	INSPECT FUEL TANK ASSEMBLY

HINT:

Inspect the fuel tank assembly and fuel sender assembly for deformation, foreign matter or an improperly installed fuel receiver gauge, as this may be the cause of the fuel receiver gauge malfunction.

(a) Visually check the fuel tank assembly for any abnormalities.

(b) Check if there is an excessive amount of foreign matter in the fuel tank assembly.

(c) Visually check the fuel sender gauge assembly for damage and confirm that it operates correctly.

(d) Check the installation condition of the fuel tank assembly and fuel sender gauge assembly.

Result	Proceed to
Normal	A
Appearance of the fuel tank assembly is abnormal	B
There is an excessive amount of foreign matter in the fuel tank assembly	C
The fuel sender gauge assembly is visually damaged or does not operate correctly	D
The fuel tank assembly or fuel sender gauge assembly is not installed correctly	E

A

REPLACE COMBINATION METER ASSEMBLY

B

REPLACE FUEL TANK ASSEMBLY

C

CLEAN INSIDE OF FUEL TANK ASSEMBLY

D

REPLACE FUEL SENDER GAUGE ASSEMBLY

E

INSTALL FUEL TANK ASSEMBLY OR FUEL SENDER GAUGE ASSEMBLY CORRECTLY

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